Fouling Factors

Fouling Factors
The use of fouling factors is a common method to account for the expected fouling tendency
of a process and maximize the runtime between cleaning for shell and tube heat
exchangers. Fouling factors are selected to represents the fouling expected just before
cleaning time. This method results in the heat exchanger performing better when clean and
just meeting the heat transfer requirements when fouled.
Both physical and economical considerations must be reviewed when selecting the
appropriate fouling factors. Physical considerations that influence the selection of the
fouling factors are:
nature of fluid
type of fouling
fluid temperature
wall temperature
material of construction
fluid velocity
Economic considerations that influence the fouling factors selection are:
Initial purchase cost of the exchanger
Variations of cost with size
Frequency of cleaning required
Cost of cleaning (including loss of production)
Fluid pumping cost
Desired net return on investment
The initial purchase cost increases with increasing fouling resistance while cleaning and
down-time expenses generally decrease with increasing fouling resistance. However,
using large fouling factors can lead to more fouling than anticipated and result in more
frequent cleaning. Selecting the optimum fouling factors involves satisfying conflicting
goals.
The link below lists typicall fouling factors.
Typical Fouling Factors

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Fouling Factors
Fouling is a function of the system and the equipment used. Parameters which influence the
fouling rate in a system include: the type of fluid, the type of heat exchanger, the
temperatures, the velocities and the materials of construction. The actual fouling rate is
different for each application.
There are numerous resources for fouling factor values. The best source is from existing
operating facilities. When production data is available, it can be used to calculate the actual
fouling factors for the system. Together with the maintenance and cleaning history, this
provides the best resource for selecting the fouling factors for a particular application.
However, when production data is not available, one must rely on other sources. Over the
years, typical fouling factors have been compiled for various systems and fluids. The tables
below show some of these typical fouling factors:
Process Fluids
Fouling Resistance
(ft2-F-hr/BTU)
Oils
Fuel Oil #2
0.002
Fuel Oil #6
0.005
Transformer Oil
0.001
Engine Lube Oil
0.001
Gases and Vapors
Acid gas
0.002 - 0.003
Ammonia vapor
Chlorinated hydrocarbons vapors
0.001
0.001 - 0.0015
Chlorine Vapor
0.002
CO2 vapor
0.001
Compressed Air
0.001
Hydrogen
0.0005
Hydrogen (saturated with water)
0.002
Light Hydrocarbon vapors (clean)
0.001
Natural Gas
Natural Gas Flue Gas
Nitrogen
Polymerizable vapors (with

inhibitor)
0.001 - 0.002
0.005
0.0005
0.003 - 0.03
Refrigerant Vapors (oil bearing)
0.002
Solvent Vapor
0.001
Stable Overhead Products
0.001
Steam (non-oil bearing)
Steam (exhaust, oil bearing)
0.0005
0.0015 - 0.002
Liquids
Ammonia Liquid
0.001
Ammonia Liquid (oil bearing)
0.003
CO2 Liquid
0.001
Chlorinated hydrocarbons liquid
0.001 - 0.002
Chlorine Liquid
0.002
DEG & TEG Solutions
0.002
Ethylene Glycol Solutions
0.002
Gasoline
0.002
Heavy Fuel Oils
0.005 - 0.007
Heavy Gas Oil
0.003 - 0.005
Hydraulic Fluid
0.001
Kerosene
0.002 - 0.003
Light Gas Oil
0.002 - 0.003
Light hydrocarbon liquid (clean)
0.001
MEA & DEA Solutions
0.002
Naphtha and Light Distillates
0.002 - 0.003
Organic Heat Transfer Liquids
0.002
Refrigerant Liquids
0.001
Water
water temperature
water velocity
Fouling Resistance
Fouling Resistance
(ft2-F-hr/BTU)
(ft2-F-hr/BTU)
125F or less
over 125F
3 ft/s or less
over 3 ft/s
3 ft/s or less
over 3 ft/s
Boiler Blowdown Water
0.002
0.002
0.002
0.002
Brackish Water
0.002
0.001
0.003
0.002
0.0005
0.0005
0.0005
0.0005
Cooling Tower Water (treated)
0.001
0.001
0.002
0.002
Cooling Tower Water

(untreated)
0.003
0.003
0.005
0.004
Condensate
City or Well Water
0.001
0.001
0.002
0.002
River Water (minimum)
0.002
0.001
0.003
0.002
River Water (average)
0.003
0.002
0.004
0.003
River Water (muddy or silty)
0.003
0.002
0.004
0.003
0.0005
0.0005
0.001
0.001
0.001
0.0005
0.001
0.001
Sea Water
Treated Boiler Feed Water
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Fouling Factors

Economic considerations that influence the fouling factors selection are:

Initial purchase cost of the exchanger

Variations of cost with size

Frequency of cleaning required

Cost of cleaning (including loss of production)

Fluid pumping cost

Desired net return on investment

Typical Fouling Factors

Engine Lube Oil

Gases and Vapors

Chlorinated hydrocarbons vapors

Hydrogen (saturated with water)

Light Hydrocarbon vapors (clean)

Natural Gas Flue Gas

Polymerizable vapors (with

Refrigerant Vapors (oil bearing)

Stable Overhead Products

Steam (non-oil bearing)

Steam (exhaust, oil bearing)

Ammonia Liquid (oil bearing)

Chlorinated hydrocarbons liquid

DEG & TEG Solutions

Ethylene Glycol Solutions

Heavy Fuel Oils

Heavy Gas Oil

Light Gas Oil

Light hydrocarbon liquid (clean)

MEA & DEA Solutions

Naphtha and Light Distillates

Organic Heat Transfer Liquids

Boiler Blowdown Water

Cooling Tower Water (treated)

Cooling Tower Water

City or Well Water

River Water (minimum)

River Water (average)

River Water (muddy or silty)

Treated Boiler Feed Water

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