Investigation of zirconium (Zr) coated heat exchanger surface for the enhancement of heat transfer and retardation of mineral fouling

Background: Fouling is a major problem in many industrial heat exchangers as in these devices water has been used for heat exchanging purposes. With the commencement of foulants deposition on heat exchanger surface the performance of heat exchangers is deteriorated due to lower thermal conductivity of the deposits formed on the heat exchanger surface. This study investigated the heat transfer and mitigation of CaCO₃ fouling by applying zirconium coating layer on heat exchanger surface. Methods: Zirconium was chosen as a coating material because of its surface adhesion and one of the best corrosion resistance materials. The Physical Vapor Deposition approach was implemented to develop a coating layer on heat exchanger surface. Heat transfer was investigated at numerous temperatures and flow rates to examine the impact of coating on heat transfer. Fouling experiments were conducted to examine the CaCO₃ accumulation on the uncoated SS316L and Zirconium coated surfaces. After the fouling experiments, the coupon was disassembled from the test segment for the investigation of surface texture, after fouling effect and the morphology of deposits was assessed by using Field Emission Scanning Electron Microscopy (FESEM). Significant findings: Results reveal that the Zirconium coated surface declined the fouling deposition and improved the heat transfer.