Thermal-Hydraulic Performance of Shell-and-Tube Heat Exchangers Fouled by Industrial Process Fluids

Abstract

Fouling in shell-and-tube heat exchangers significantly affects thermal efficiency, pressure drop characteristics, and operational reliability in industrial process systems. Accumulation of deposits from industrial process fluids reduces heat transfer performance and increases energy consumption, maintenance frequency, and operational costs. This study investigates the thermal-hydraulic performance of shell-and-tube heat exchangers subjected to fouling under varying industrial operating conditions. A comprehensive experimental and numerical analysis was conducted to evaluate the influence of fouling layer thickness, fluid flow rate, temperature variation, fluid properties, and exchanger geometry on heat transfer efficiency and hydraulic behavior. Computational fluid dynamics and thermal performance modeling techniques were employed to analyze temperature distribution, flow turbulence, pressure loss, and fouling resistance within the heat exchanger system. Results demonstrated that increasing fouling severity significantly reduces overall heat transfer coefficient and thermal effectiveness while simultaneously increasing pressure drop and pumping power requirements. The study further revealed that fouling accumulation alters fluid flow distribution and promotes localized thermal resistance, thereby reducing operational stability and energy efficiency. Comparative analysis indicated that optimized flow conditions and enhanced cleaning strategies can substantially mitigate thermal performance deterioration and improve exchanger reliability during continuous industrial operation. Additionally, predictive thermal-hydraulic modeling enabled accurate estimation of fouling progression and supported preventive maintenance planning for industrial heat transfer systems.