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  • ANTIFOAMING AGENTS PERFORMANCE EVALUATION *

    Monazir Imam, Ata Yaseen Abdulgader, Ghulam M. Mustafa, Radwan Al-Rasheed and Ibraheem Al-Tissan

    Research and Development Center, P.O Box 8328, Al-Jubail, Kingdom of Saudi Arabia

    Abdul Salam Al-Mobayed and Anwar Ehsan

    Al-Jubail Desalination & Power Plant, Al-Jubail, Saudi Arabia.

    ABSTRACT

    Distillate contamination by salt carry over due to excessive foaming in multistage flash (MSF) distillers and detrimental foaming in deaerator section have been reported in Saline Water Conversion Corporation (SWCC) and other desalination plants. Application of suitable antifoaming agents not only maintains high quality of distillate but also improves release of dissolved oxygen in the deaerator section, thus improving the operating efficiency of MSF plants. Brose Chemical Company (BCC) and Albright and Wilson Limited (A&W) developers of antifoaming agents BCC-74M and Albrivap AF-2 respectively collaborated with SWCC in conducting trial runs to show that their products are as effective and economical as the one currently being used in SWCC plants.

    Foam control, non interference with the antiscalant performance, distillate purity, and stability over a wide range of temperatures at low dosage levels were some of the important criteria taken while evaluating the performance of these antifoaming agents. Compatibility of these agents were determined initially in the laboratory followed by field trial runs in MSF pilot plant and commercial plants of Al-Jubail phases I&II in order to check the above criteria. During MSF plant runs distillate conductivity and make-up feed dissolved oxygen(DO) levels were maintained in the ranges of 1-27 S/cm and 5-47 ppb respectively. The higher DO was in Al-Jubail Phase I where deaeration takes place in the last stage of the distiller. These results were achieved at antifoam dose rates of 0.15 to 0.035 ppm. Once again higher dose rates at Al-Jubail Phase I were needed for the same reason mentioned above. Based on these results, one could say that data observed during these test runs showed satisfactory performance and thus conclude that these agents are comparable with the currently used antifoaming agents and can be effectively used in MSF plants of SWCC. *Presented in Second Acquired Experience Symposium, September, 1997, Al-Jubail *This paper is based on Technical Reports No. TR 96002 and TR 96005.

    1382

  • INTRODUCTION Seawater is not a pure liquid. In addition to 3-4 % inorganic salts, it contains traces of

    organic compounds that have surface-active properties. As a surface phenomenon, minute

    quantities of organic compounds and fine particulate matter can promote foaming. Some of

    the few basic principles related to foaming in MSF desalination plants are highlighted [1]

    below:

    1. Pure liquid do not foam. Presences of surfactant impurities are necessary for foaming to

    occur and stabilize.

    2. Foams are unstable and tend to collapse quickly to separate gas and liquid components.

    Concentration of surfactant impurities opposes this collapse by several mechanisms.

    3. The foam stability depends on many factors. Some of which are film viscosity, surface

    elasticity, electrical repulsion and gaseous diffusion. Disruption of these conditions

    enables to control foaming.

    Antifoaming agents are usually non-ionic surfactants with temperature dependent solubility.

    They have the important characteristics of low volatility, ease of dispersion, strong spreading

    power and surface attraction and orientation. They act to lower the surface tension of the

    vapor/liquid interface, reducing liquid film strength and surface viscosity and speeding

    drainage from bubbles. Summaries of foam control agents used in various applications other

    than desalination have been reported [2-3].

    The effectiveness of antifoaming agents among more than 60 candidates from seven different

    chemical classes was determined [1]. The effectiveness of the best one of these was further

    verified in a 90 day trial run at a TBT of 108 oC on 2.2 MGD MSF recycle plant in Cura-

    Cao(Werkspour) of the Dutch Antilles. In this test foaming was suppressed without affecting

    the scale control agent at a dose rate of 0.03-0.05 ppm[1]. The effect of this antifoam on

    brine heater and flash chamber scaling using single stage flash evaporator (as a simulation

    module) at 120oC outlet temperature with normal recycle configuration was also studied[4].

    Detrimental effect of foaming is not only found in MSF distillers but also reported in

    deaerator section [5-8]. It has been reported that during the commissioning period of Jeddah

    phase III, the deaerator was not performing according to design [5]. A detailed investigation

    of this problem resulted in the replacement of existing liquid distribution device with a more

    1383

  • controlled and suitable system. The initial application of this device on site immediately

    showed an improvement in oxygen level from 200 down to about 80 ppb. However, this was

    still significantly above the guaranteed figure and after a study of the particular antifoam is

    being used, it became evident that the antifoam being used at the site was not suitable for the

    full-scale plant deaerator. The antifoam normally used was adequate and sufficient for

    controlling foam within the distillers, but did not perform satisfactorily at temperature levels

    of the deaerator. Utilization of alternate antifoam, capable of operating at temperatures of

    30oC and below, immediately improved the deaerator performance. This agent brought down

    oxygen levels to less than 20 ppb as was desired.

    Thus one can say that antifoaming agents should also serve the purpose of preventing

    foaming either in the first few stages or in the deaerator, therefore, improving release of

    dissolved oxygen in the deaerator hence preventing carry over of salts to ejector system[6]. In

    other words foaming is a major reason for maloperation of deaerator columns [7]. The

    effluent dissolved oxygen concentration is strongly dependent on the combined action due to

    antifoam dosage rate and stripping steam [8]. Hence the importance of proper antifoam

    dosage and stripping steam flow rate on the satisfactory performance of deaerator columns

    must be emphasized. It has been further reported that deaeration of seawater can be effective

    in lowering oxygen content down to the range of 80-200 ppb as demonstrated in a test using

    single spray nozzle. However, for better deaeration i.e., to reduce oxygen level down to less

    than 20 ppb, antifoaming agents are to be introduced upstream of deaerator nozzles. Efforts

    to improve the performance and optimize the dosing rate of antifoaming agents are still

    continuing. In this context certain new advances have been attained particularly by owners of

    MSF plants in evaluating and optimizing the use of available antifoaming agents [9-10].

    Antifoaming agents BCC-74M and Albivap AF-2 are claimed to be highly effective to

    prevent foaming problems in MSF distillation plants. In addition to this, these antifoaming

    agents are further characterized by some important and promising features such as their

    efficiency over a wide range of temperature at low dosage levels, stable dispersion with

    distillate at typical dosing solution concentrations, and economic viability. Table 1

    specifically identify the important properties of these two antifoaming agents.The primary

    objective of these trial runs is to evaluate the performance of BCC-74M and AF-2 in

    1384

  • controlling foams without disturbing the effectiveness of scale control additives in MSF pilot

    plant and commercial plants of Al-Jubail phases I&II.

    DESCRIPTION OF TESTS Field trial runs on these antifoaming agents were conducted on an MSF Pilot Plant and

    commercial plants of Al-Jubail Phases I&II. Table 2 summarizes the test conditions of these

    antifoaming agents. Antifoam dose rate at pilot plant was 0.04 ppm, whereas the dose rate at

    phase I was varied between 0.15-0.1 ppm. Dose rates for all ten units of Phase II (unit 11 to

    20) were varied between 0.05-0.04 ppm. Dose rates of all the other units of phase II except

    unit 12 were further reduced to the normal antifoam dose rate of 0.035 ppm. The antifoam

    feed tanks concentrations were checked once per day (for each batch preparation) by

    chemical analysis to be sure that the concentration was maintained. Solutions of 0.5 %

    antifoam were separately injected into the make up seawater upstream of deaerators of pilot

    plant and all units of phase II The solution concentration at Phase I was 1.0%. On-line ball

    cleaning systems were operated as usual during all these tests to maintain high distiller

    performance.

    Miscibility behavior of these antifoaming agents in water was determined in the laboratory

    prior to field trial runs. Sea water and brine chemistry, distillate conductivity, deaerator

    performance, distillate contamination by organic carry over and potential for bacterial growth

    and aftergrowth were closely monitored during performance evaluation of these antifoaming

    agents. Performance test monitoring also required data logging of flow, temperature and

    pressure measurements. The most important flow monitoring points were recirculating brine,

    make-up seawater, distillate, brine heater condensate, and last yet quite important were the

    monitoring of antiscalant and antifoaming agents dose rates. Brine heater terminal brine

    recycle and vapor temperatures were also monitored. These data were used to calculate the

    heat transfer coefficient of brine heater, plant performance ratio or gain output ratio.

    RESULTS AND DISCUSSION Results of miscibility tests for the antifoaming agents BCC-74M and AF-2 reveal that at a

    concentration of 0.5% and 1.0%, the antifoam solution remains homogeneous up to 24 hours

    and then starts settling gradually. This observation was also confirmed during testing in Al-

    Jubail commercial MSF units, where settling of antifoam in the preparation tanks as well as

    1385

  • clogging in the antifoam dosing system were not noticed. Hence, it can be said that the

    antifoaming agents BCC-74M and AF-2 are fully dispersible in water at the solution

    concentration of 1.0% and 0.5% as normally practiced in phase I and C2/C3 units of Al-

    Jubail Phase II plants. On the other hand, settling started much earlier for higher

    concentration of 1.5% i.e., as the residence time increases; turbidity of antifoam solution was

    noticed to decrease significantly. Thus it is essential that for such high concentration

    extensive miscibility tests have to be conducted taking into consideration actual plant

    operating conditions.

    As earlier stated, excessive foaming in the MSF distiller results in the contamination of

    distillate by salt carry over. Antifoaming agents are added to the make-up feed to maintain

    distillate quality by preventing foaming and hence salt carry over. Graph (a) of Figures 1

    through 4 show the variation in distillate conductivity versus time. The maximum values of

    distillate conductivity in the pilot plant and commercial units of Al-Jubail Phase II were

    recorded to be 27 and 4S/cm respectively for antifoaming agents BCC-74M and AF-2

    except in unit 13 for AF-2, where the conductivity was found varying in the range of 8-20

    S/cm. These values are well within the design acceptable limits and satisfying the

    specification of these plants. Higher distillate conductivity in unit 13 was due to the fouled

    condition of demister pads prior to the trial run of AF-2, while in Pilot plant is mainly due to

    the violent flashing in limited number of distiller stages. Moreover, the lower demister height

    and the limited overall volume of MSF pilot unit contribute to the higher conductivity of the

    distillate.

    Detrimental foaming in the deaerator section has been reported in many MSF desalination

    plants. Selection of proper antifoam improves deaerator performance [5-8]. Hence,

    monitoring of dissolved oxygen in the make up feed downstream of deaerator was essential

    to assess the ability of the antifoaming agents in preventing foaming in deaerator section and

    subsequently maintaining acceptable oxygen levels. Variation in dissolved oxygen in make

    up stream after deaeration is shown in graph (b) of Figures 1 through 4. The maximum level

    of dissolved oxygen in make-up stream of Al-Jubail pilot plant as well as phase II units

    varied in the range of 9-15 ppb for both antifoaming agents. These values were within the

    acceptable limits of less than 20 ppb after deaeration, which implied the integrity of these

    antifoaming agents within the operating temperature range of phase II deaerators. On the

    1386

  • other hand the dissolved oxygen content in the recycle brine in phase I varied in the range of

    45-47 ppb. These values are considerably higher compared to pilot and phase II units because

    (as earlier pointed out) at phase I deaeration takes place within the last stage of the distiller in

    the absence of external deaerator.

    Maintenance of effective scale control is the most crucial factor in MSF desalination process.

    Some of the effective antifoams may reduce antiscalant activity resulting in 40-50% more

    scale[1]. Therefore, the compatibility of these antifoaming agents with antiscalant under use

    was checked by calculating plant performance ratio (PR) or gain output ratio (GOR) along

    with the overall heat transfer coefficient (HTC). Variation in brine heater heat transfer

    coefficients in pilot and Al- Jubail Phase I plants are shown in graph (c) of Figures 1 and 2.

    These values of heat transfer coefficients in both plants remained stable throughout the test

    runs for both antifoaming agents and did not show any kind of deterioration in their

    performance at top brine temperatures (TBT) of 112 and 90 0C in the same order as above.

    Brine heater heat transfer coefficients of unit 12 were also found stable at a TBT of 104 0C as

    shown in graph (c) of Figure 3. Heat transfer coefficients of brine heater in unit 13 showed

    some variation in the case of BCC-74M only as shown in graph (c) of Figure 4, which can be

    attributed to load change. The calculated performance parameters in terms of Gain Output

    Ratio (GOR) in pilot plant and Al-Jubail phases II&I are shown in graph (d) of Figures 1

    through 4. During the trial runs, there was no marked decline in the performance of any

    distiller under test. These results basically indicate that no significant scale precipitation took

    place in brine heaters or in the heat recovery section during trial runs using these antifoaming

    agents. Some specific conditions and results obtained during these tests are also shown in

    Tables 3 and 4, which also confirm the effectiveness of these two antifoaming agents

    It is also possible that the antifoaming agents may contaminate the distillate by its

    constituents. Frequent analysis of distillate was therefore necessary to ascertain the

    presence/absence of any organic pollutants carried over into the distillate. Organic carryover

    was monitored by Gas Chromatography-Mass Spectrometer (GC/MS) technique using

    USEPA 625 method. Figure 5 represents chromatogram of the distillate samples obtained by

    GC/MS. It can be seen from the figure that neither the antifoam as whole nor any toxic

    components derived from antifoaming agents were carried over into the distillate. Hence it

    1387

  • can be stated that the distillate purity was unaffected during the trial runs of these

    antifoaming agents.

    Increased bacterial after growth and consequently higher fouling potential could be due to

    supply of nutrients by the antifoaming agent. Bacterial growth and after growth were thus

    determined in samples of: (i) raw seawater (ii) make-up feed (iii) antifoam mixing tank, and

    (iv) product water which is used as diluent in mixing tank. Results of bacterial counts for

    bacterial growth and after growth potentials are presented in Tables 5 and 6. These showed

    that bacterial after growth obtained from samples containing antifoam were either lower or

    similar to raw sea water samples. It is therefore concluded that the antifoam is not enhancing

    nor contributing to the bacterial growth and would not be anticipated to result in fouling of

    antifoam dosing system.

    CONCLUSIONS

    1. Antifoaming agents BCC-74M and AF-2 solutions were fully dispersible in water at a

    concentration of 0.5 and 1.0%, as no settling of antifoam in preparation tanks nor

    clogging in the dosing system was noticed.

    2. Bacteriological analysis of make-up water and antifoaming agents showed that, they are

    not a source of contamination. Furthermore after growth potentials for bacteria indicated

    that the antifoaming agents were not enhancing growth and consequently biofouling.

    3. Dissolved oxygen levels in the make-up feed after deaerations were within acceptable

    limits of less than 20 ppb. The only exception of Al-Jubail Phase I unit which varied

    between 45-47 in the recycle stream.

    4. Distillate quality was maintained within the acceptable range of 1-27 S/cm. On the

    other hand carry-over of any steam-volatile component related to the antifoam was also

    not detected, thus maintaining the distillate purity over the entire duration of these test

    runs.

    5. At dose rates of 0.15 down to 0.035 ppm these antifoaming agents were effective at all

    MSF operating temperatures (TBT 90-1120C) and found compatible with the antiscalant

    presently under use. Moreover, the overall performances of monitored distillers were

    found satisfactory during these trial periods, (see attached Tables 3 and 4 also Figures 1

    to 4). Hence, it can be concluded that the subject antifoaming agents are acceptable for

    MSF application. 1388

  • RECOMMENDATIONS

    1. The results of these evaluation tests indicate that the performance of BCC-74M and AF-

    2 are quite satisfactory and can be used in MSF plants as effective antifoam agents.

    2. The observed performance of antifoaming agents BCC-74M and AF-2 in pilot and

    commercial plants of Al-Jubail phase II at dose rates of 0.04 and 0.035 ppm and TBT of

    112 and 92 0C respectively was satisfactory. It is therefore recommended that further

    dose rate optimization is to be carried out.

    1389

  • REFERENCES 1. Auerbach, M. H., O.Neill J. J., Reimer R. A. and Walinsky S. W. (1981) Foam Control

    Additives in MSF Desalination, Desalination, 38, 159-167. 2. Owen, M. J.(1985) Antifoaming Agents, In Encyl. of polymer Science and Engineering,

    2nd edn; (Edited by Mark, H. F., Bikales N. M., Overberger C. G. and Menges G.) A Wiley Interscience, USA, 164-171.

    3. Lichtman, J. and Gammon T. (1979) Defoamers, in Encycl. of Chemical Technology, 3rd

    edn; Edited by Kirk-Othmer) A wiley Interscience, USA, 430-448. 4. Auerbach, M. H. and Carruthers M. S. (1979) Laboratory Application Testing of

    Desalination Antiscalants, Desalination, 31, 279-288. 5. Abkar, A. A., Girgis F. and Von Loebbecke H. D. (1986) Operating Experience Related to

    SWCC Desalination plant Jeddah III in the Kingdom of Saudi Arabia, Topics in Desalination, SWCC, Saudi Arabia, 104-105.

    6. Nada, N., Khumayyis D. and Al Hussain M. (1985) Economical Evaluation of Al-Khobar

    Phase II 50 MIGPD at Three Different Mode of Operation, Desalination, 55, 43-54. 7. Eckert, J. S. (1970) Selecting the Proper Distillation Column Packing, Chemical

    Engineering Progress, 66(3), 39-44. 8. Rabas, T. J., Inoue S. and Shimizu A. (1987) An Update on the Mass Transfer of

    Counterflow, Packed Deaerators Containing Pall ring Packing, Desalination, 66, 91-107. 9. Imam, M., Abdulgader A. Y., Mustafa G. M., Al-Rasheed R., Al-Tissan I., Al-Mobayed

    A. S., Ehsan, A. and Dayley D. (1996) Performance Evaluation of Antifoam Additive BCC-74M on MSF Pilot plant and Commercial Plants of Al-Jubail Phase I&II, R&D Center, SWCC, Al-Jubail, Technical Report No. TR96002.

    10.Pujadas, F., Fukomoto Y. and Isobe K. (1991) Performance Test of Antiscalant

    Aquakreen KC-550 under a wide range of temperature conditions at the MSF Desalination Plant in Abu Dhabi, Desalination, 83, 65-75.

    1390

  • Table 1. Technical specifications of BCC-74M and AF-2

    S.No. Properties AF-2 BCC-74M 1 Specific gravity (20 0C) 1.02 1.02 2 pH(1%aqueous

    dispersion) 7 7

    3 Solubility in water Dispersible Dispersible 4 Appearance Pale amber

    liquid Pale yellow liquid

    5 Odor Faint Oily

    Table 2. Test Conditions

    S.No.

    Parameters AF-2 BCC-74M

    PP Ph II PP Ph I Ph II 1 Test duration

    (days) 7 30 7 7 21

    2 No. of units (distiller no.)

    1 10 (11-20) 1 1(5) 10 (11-20)

    3 TBT ( 0C) 112 105/92 112 88 105/92 4 Concentration

    ratio 1.38-1.4 1.34-1.41 1.38-1.4 1.39-

    1.41 1.34-1.41

    5 Antiscalant used DSB(M) BEV2000 DSB(M) DSB(M) DSB(M) 7 Antiscalant dose

    rate (ppm) 2.0 1.5/1.0 2.0 1.0 1.5/1.0

    8 Antifoam dose rate (ppm)

    0.04 .05/.04/.035 0.04 0.15/0.1 .05/.04/.035

    9 Antifoam tank conc.

    0.5% 0.5% 0.5% 1.0% 0.5%

    1391

  • Table 3. Typical Plant Performance Data

    Parameters Unit AF2 BCC-74M PP U12,

    PhII U13, PhII

    PP U5, PhI

    U12, PhII

    U13, PhII

    Condensate m3/hr 0.35 125 125.8 0.35 128 132 117-136 Flow Brine recycle 6.53 9200 10000 6.53 10800 9210 10300-

    10500 Rate Production 1.15 1060 945 1.15 970 1121 900-1050

    Make up 2.15 3025 2500 2.15 2750 3175 2100-2650

    Blow down - 2100 1725 - 1750 2190 1700-2150

    Inlet to Brine Heater oC 90 96.3 88.2 90 80.6 96 84-88 Outlet of Brine Heater 112 103.1 94.8 112 88 104 92-95

    Temp. Condensate 117 108.8 100.3 117 92 109 95-100 Recovery tube inlet 35 34.5 36 35 34 35 34 Make up 34 34 36 34 34 35 34

    Seawater 18 28 28 18 24 27 27 Brine Heater HTC W/m2 C 4030 2662 2800 2850 3715 2914 2500-

    4200 GOR (kg distillate/ kg

    steam 2.8 8.77 7.77 2.4 7.84 8.76 7.6-8.17

    1392

  • Table 4. Typical Chemical Analysis Data

    Parameters Unit AF-2

    BCC-74M

    PP U12, PhII

    U13, PhII

    PP U5, PhI

    U12, PhII

    U13, PhII

    Chlorides ppm 22727 23550 23500 22350 23700 23660 23660 Sea water Conductivity S/cm 59600 60200 60200 59350 61200 60786 60783

    M-alkalinity as CaCO3 ppm 129 131 131 130 131 131 131 pH - 8.36 8.24 8.24 8.23 8.35 8.27 8.27 Residual chlorine ppm - 0.3 0.3 - 0.25 0.25 0.25

    Make-up Dissolved oxygen ppb 6-9 10-17 10-17 5-9 - 12 12 Chlorides ppm 31148 31553 32834 31273 33200 31684 33019

    Recycle Brine

    Conductivity S/cm 73800 76400 79500 76837 80450 76717 79950

    pH - 8.68 8.64 8.61 8.61 8.71 8.72 8.65 Conc. ratio - 1.38 1.34 1.4 1.39 1.4 1.34 1.39

    Dissolved oxygen ppb - - - - 45-47 - - Blow down Chlorides ppm 34953 35375 36250 34820 36268 36096 36383 Conductivity S/cm 80100 83600 85700 84890 86040 85200 86000 pH - 8.8 8.85 8.75 8.71 8.78 8.85 8.75 Distillate Conductivity S/cm 23.1 1.89 9.97 25-27 1.55 2.57 1.53 pH - 6.62 6.82 6.76 6.67 6.75 6.75 6.73

    1393

  • Table 5. Mean counts of bacterial growth and after growth Potential (N=9) of various samples on day 2

    Sample Bacterial Count (cfu/ml) AF-2 BCC-74M

    Zero hour 24 hours 72 hours Zero hour 24 hours 72 hours

    Raw Seawater 4.2 x 103 8.1 x 104 1.9 x 105 4.2 x 103 8.1 x 104 1.9 x105

    Mixing tank 3.9 x 102 3.2 x 105 5.1 x 105 - 3.9910 5 1.82 x 105

    Make-up feed 4.9 x 103 3.9 x 105 3.9 x 105 - 4.7 x 105 1.82 x 105

    Product water 3.0 0 0 3.0 0 0

    Table 6. Mean counts of bacterial growth and after growth

    Potential (N=9) of various samples on day 7

    Sample Bacterial Count (cfu/ml)

    AF-2 BCC-74M

    Zero hour 24 hours 72 hours Zero hour 24 hours 72 hours

    Raw Seawater 3.7 x 103 7.9 x 104 1.8 x 105 1.67 x 102 - 3.17 x 106

    Mixing tank 2.9 x 103 1.3 x 104 1.0 x 105 5.73 x 104 - 2.8 x 103

    Make-up feed 2.9 x 103 1.0 x 105 2.2 x 105 2.93 x 103 - 4.07 x 105

    1394

  • Figure 1. Performance of Antifoaming Agents in RDC Pilot Plant at Al-Jubail

    20

    22

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    26

    28

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    Co

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    Graph (a)

    Graph (b)

    Graph (c)

    Graph (d)

    1395

  • 0

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    Figure 2. Performance of Antifoaming Agent BCC-74M in Al-Jubail Phase I Unit 5

    Graph (a)

    Graph (b)

    Graph (c)

    Graph (d)

    1396

  • Figure 3. Performance of Antifoaming Agents in Al-Jubail Plant Phase II Unit 12

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    2 K BCC(HTC) AF2(HTC)

    Graph (a)

    Graph (b)

    Graph (c)

    Graph (d)

    1397

  • Figure 4. Performance of Antifoaming Agents in Al-Jubail Plant Phase II Unit 13

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    5

    0 100 200 300 400 500 600 700

    Hea

    t T

    ran

    sfer

    Co

    eff.

    , kW

    /mK

    BCC(HTC) AF2(HTC)

    Graph (a)

    Graph (b)

    Graph (c)

    Graph (d)

    1398

  • Figure 5. Chromatograms of distillate samples

    BCC-74M

    AF-2

    1399