Computer technology is leading to more accurate sizing and rating methods for process equipment. Heat exchangers are designed with high-precision prediction methods and complex numerical techniques to account for the local flow and temperature conditions. Fouling mitigation is just changing from an art to a science-based technology. The real benefits of sophisticated design codes will not be achieved without reliable fouling prediction methods and mitigation techniques that can be incorporated into the design phase. Recent developments in the computer technology provide an opportunity to productively use fouling information that is scattered in the literature, industry log books, and in reports. A long-term goal for the industry is to develop a knowledge-based system for designing and operating heat exchangers with a minimum impact of water fouling. The major challenges to develop the knowledge-based system are as follows: 1. Compilation and organization of the fouling data 2. Easy access by both research organizations and industry 3. Development of a logic system for interpreting the fouling data 4. Industrial acceptance of such knowledge-based systems The fouling data and analyses reported in the literature are often inadequately utilized. To effectively utilize these data, compilation and organization of fouling information are major tasks and challenges for research organizations and industries. This task is more important for the fouling-mitigation technology as compared to other engineering areas. It is hard to imagine that there could be a single correlation with a given set of parameters that can be used to predict the rate of fouling or determine the threshold fouling conditions. One has to rely on the best possible approach to mitigate fouling for a given set of conditions. In the absence of such information, either mitigation methods are overutilized, with high chemical costs, or underutilized, with high maintenance and production costs. Ferraris et al. [54] introduced an approach for compiling the fouling data in the literature. A major cooperative effort is required to carry out such a major challenge for compiling and organizing data. The fouling data and analyses must be accompanied by physical and chemical parameters, without which the data have little value. The next step in information technology is to develop a logic system to utilize the database for interpreting the results. Waltzing et al. [13] discussed a possible approach for utilizing a so-called expert system for selecting a strategy for fouling control. However, before such an expert system can be developed, it is essential to develop a knowledge-based system to access and interpret the fouling information. The logic for knowledge-based systems can be structured as shown in Fig. 19. The system is a computerized tool for aiding the engineer to design and operate the heat exchanger with the best possible strategy that can be used for mitigating fouling. Technology overview Computer technology requires a completely different methodology of engineering design. It has revolutionized the speed and efficiency of the plastic design functions. The more the entire design function is studied, the more repetitive tasks are uncovered in that function. The computer's ability to perform these tasks untiringly and with blazing speed is the basis for these productivity gains. The computer continues to provide the engineer with the means to simplify and more accurately develop a design timewise and costwise. It provides a better understanding of the operating requirements for a product design, resulting in maximizing the design efficiency in meeting product requirements. The computer is able to convert a design into a fabricated product, providing a faster manufacturing startup. Other benefits resulting from the computer technology include (1) ease of developing and applying new innovative design ideas, (2) fewer errors in drawings; (3) good communications with the fabricator, (4) improved manufacturing accuracy; and (5) a faster response to market demand. CAD, CAE, CAM, CAA, and CAT are the directions of all types of plastics product design, mold or die making, and the fabricating line. The number and complexity of plastic products being produced are greater every year, but the number of experienced product designers, mold/die designers, and fabricators generally have not kept pace. The answer to this “people power” shortage has been to increase “design to productivity” through the use of CAD/CAE/CAM/CAA/CAT.
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