Hi,
I am trying to calculate the heat exchanger efficiency of a system heating a sludge using hot water.
The boilers on the system heat the water to a set point of 70C. The water flow is constant because the water is low in solids and the incoming water temperature is read at 68C consistently.
I cleaned the heat exchanger today and the sludge was incoming at 30C and outputting at 36C, this varies though from 15C input up to 45C input. It is a spiral heat exchanger.
The hot water pump flow rate is 30m3/hr or 8.4kg/s
The sludge pump flow is also 30m3/hr or 8.4kg/s (No flow meter fitted but assuming this value today after cleaning not including pump wear)
The sludge is contaminated with lots of heavy fibourous solids. The heat exchanger is blocking over time, gradually until it gets so bad the sludge pump blows its mechanical seals. I clean the heat exchanger after about a week to stop the pump damage. As the sludge circuit of the heat exchanger blocks the flow rate decreases and the heat transfered to the sludge drops.
The rate of blocking varies between 2 days and one month depending on the upstream sludge processing which impact the sizes of the fibourous solids coming through the exchanger.
The temperature readings are measured on screen in and out on both circuits of the heat exchanger. Ideally I would like to have a value I can set myself where I will clean the heat exchanger (maybe when I lose 40% of the transfer efficiency)
I know this might be quite simple but my maths isnt all that good to work this out.
Thanks for your help in advance,
Rob