Estimation and sensitivity analysis of fouling resistance in phosphoric acid/steam heat exchanger using artificial neural networks and regression methods

One of the most frequent problem in phosphoric acid concentration plant is the heat exchanger build-up. This problem causes a reduction of the performance of this equipment and an increase of energy losses which lead to damage the apparatus. In this study, estimation of fouling resistance in a cross-flow heat exchanger was solved using a linear [Partial Least Squares (PLS)] and non linear [Artificial Neural Network (ANN)] methods. Principal Component Analysis (PCA) and Step Wise Regression (SWR) were preceded the modeling in order to determine the highest relation between operating parameters with the fouling resistance. The values of correlation coefficient (r(2)) and predictive ability which are equal to 0.992 and 87%, respectively showed a good prediction of the developed PLS model. In order to improve the results obtained by PLS method, an ANN model was developed. 361 experimental data points was used to design and train the network. A network containing 6 hidden neurons trained with Broyden–Fletcher–Goldfarb–Shanno (BFGS) algorithm and hyperbolic tangent sigmoid transfer function for the hidden and output layers was selected to be the optimal configuration. The Garson’s equation was applied to determine the sensitivity of input parameters on fouling resistance based on ANN results. Results indicated that acid inlet and outlet temperatures were the high relative important parameters on fouling resistance with importance equal to 56% and 15.4%, respectively.