Surface with wettability gradient — A novel approach for crystallization fouling control on the horizontal falling film flow

To manage scaling on heat transfer surfaces, using chemical-based antifouling treatments takes a toll on the environment, and related maintenance costs are significant. A unique and environmentally friendly scale mitigation strategy is developed in this work. By manipulating the scale layer distribution using surface wettability gradients, stronger flow shear and weaker scaling adhesion are achieved, facilitating self-cleaning process. Experimental work utilizes a horizontal-tube falling-film evaporator to mimic multiple-effect distillation process. A millimetric wettability pattern – alternating hydrophilic and hydrophobic regions – is created by coating stainless steel tubes. The results show scale layers (calcium carbonate) were either thicker in hydrophilic regions and thinner in hydrophobic regions or had approximately uniform thickness in both regions but cracks in scale layers near wettability boundaries. Scale layers wash-off with flow is observed on patterned tubes, demonstrating self-cleaning process. In contrast to persistent deterioration in overall HTC (heat transfer coefficient) for baseline tube (77 % of initial HTC after 192 h), HTC on patterned tubes initially increases due to surface wetting effects, then maintains roughly constant (15 % higher than that of baseline after 192 h) along with lower scale mass. This work provides a novel scaling control method, a potential "green" alternative to current industry scale-control practices.