Characterization of Water-Based Anti-Corrosion and Anti-Fouling Coating in the Heat Exchanger Tube of Gas Water Heater

Abstract

Due to the fouling and corrosion issues with gas water heater heat exchangers during use, a water-based coating is created using the sol-gel method and applied to the inner surface of the copper tube of the heat exchangers. The water-based coating can reduce the surface energy of copper that is oxygen-free by 82.40 % and has outstanding hydrophobicity. The coating's adhesion strength was 8.46 MPa, and its wet adhesion reduction rate was only 0.0375 MPa·d-1 when submerged in a bath of water at a constant temperature. Its water contact angle remained above 110° even after being abraded by sandpaper, demonstrating its excellent wear resistance. At a constant temperature of 45 °C, the corrosion experiment was carried out in salt, acid, and alkali solutions. The maximum corrosion rate of the coating was 3.24 × 10-2mg∙(cm2∙h)-1, which was only 20.85 % of that of the oxygen-free copper substrate. The dynamic fouling experiment shows that the coating can effectively inhibit fouling growth, prolong the fouling induction period and reduce the average fouling rate. By factoring in the fouling thermal resistance and the coating thermal resistance, the overall heat transfer coefficient of the copper tube was computed. The results demonstrate that after applying this water-based coating, the copper tube can continue to have a high heat transfer coefficient for an extended period, ensuring the continuous and effective operation of the heat exchanger and having practical application value.