Overview of Vapor Infusion Technology

Vapor Infusion

How vapor infusion works

Dry, oil-free compressed air is directed to a vapor infusion control device that allows airflow at a desired flow rate, duration, and frequency. When the air travels through the vapor infusion cartridge within the vapor infusion control device, the air extracts vapors from the chemical catalyst medium in the cartridge and reduces oxygen concentration in the air stream. The reduced oxygen air stream, now with chemical vapor, acts as a carrier to the heat exchanger or process equipment. The chemical catalyst vapor is infused into the water flow stream of the heat exchanger through an infusion wand or sparging system, introducing a vapor bubble cloud that includes macro-, micro-, and nanobubbles. Macro- and microbubbles help mechanically prevent fouling, while nanobubbles chemically reduce it—together forming a three-pronged approach to protecting the internal surfaces of heat exchangers and process equipment.

1. The process begins with vapor infusion, where an ultra low-dose chemical vapor catalyzes the rapid formation of dense nanobubble emulsions (~2.3×10⁸ ± 4.98×10⁶ particles/mL) in water streams—without the need for high-energy generation techniques. These nanobubbles alter interfacial charge and envelop/cluster scale-forming and other nano-fouling species. In the case of scale fouling, this interaction shifts the solubility equilibrium, promoting the dissolution of scaling deposits from internal surfaces. The resulting nanoparticle clusters are then carried away by the flow stream.
2. The dilute chemical bubble catalyst treatment, applied as low part-per billion(ppb) concentrations, help inhibit biofouling and scaling reinforcing defense against fouling.
3. Finally, macro- and microbubbles provide mechanical action by sweeping away sediments and residual foulants—including those enveloped by nanobubbles—ensuring cleaner surfaces and improved thermal performance.

Vapor infusion lowers operating and maintenance costs

Clean heat exchangers and processing equipment reduce operating costs by continuously running heat exchange close to design conditions. Maintenance costs are reduced by extending the time between cleaning protocols or by eliminating cleaning all together, which reduces the disposal of hazardous cleaning, chemical generation, handling, or release of cleaning agents into the environment.

Vapor infusion is an environmentally friendly option

Using ultra low-dose chemical catalyst to create nanobubbles to treat fouling means that very low quantities of chemicals are necessary to create high concentrations of nanobubbles (~2.3x10⁸ +/- 4.98x10⁶ particles/mL). Ultra low vapor dosing (in the form of bubbles) results in very low concentration levels (parts-per-billion) present in the process water effluent. With reduced cleaning protocol frequency, or elimination of cleaning protocol, cleaning waste that would typically be released to the environment is reduced or eliminated.

Vapor infusion as part of your decarbonization program

Fouling reduces thermal conductivity and impedes flow within the heat exchanger, resulting in increased pressure drop across the heat exchanger. The increased pressure drop requires more sea water and pump power (from the ship or processing power plant) to produce the same amount of heat transfer, thereby increasing the amount of CO2 emissions. Vapor infusion's continuous, in situ cleaning reduces or eliminates fouling and allows the heat exchangers to operate at optimum design efficiency. Clean heat exchangers reduce energy consumption, thereby increasing power plant fuel efficiency and reducing CO2 emissions.

Vapor infusion story

Vapor infusion was patented by Michael Radicone of I₂ Air Fluid Innovation, Inc. Early studies conducted with the United States Navy and commercial applications indicated a profound antifouling effect of vapor infusion treatment. The results of the studies led to the submission of an abstract and subsequent paper at the 2013 International Conference on Heat Exchanger Fouling and Cleaning held in Budapest, Hungary. The audience included researchers from various universities and industries around the world, along with corporate staff of HTRI. After hearing Michael's presentation, Claudette D. Beyer, who was President and CEO of HTRI at the time, invited Michael to present vapor infusion technology at HTRI's 2013 Global Conference & Annual Meeting of Stockholders and began discussion of collaboration.

In 2014, HTRI and I₂ Air Fluid Innovation, Inc. agreed to cooperate, market, and further develop vapor infusion for use with heat exchangers and process equipment. HTRI is now the exclusive worldwide provider of vapor infusion technology for heat exchanger and water processing applications using fluid flow (including liquid or gas). Successful heat exchanger implementations in shipping, oil rigs, geothermal and aquaculture (that use water as coolant) has led to an expansion of commercial use in these applications.

In 2024, Michael received the Mike Ackrill Award for his presentation, The Science, Creation and Environmental Impact of Vapor Infusion Nano Bubbles. This award is given annually by the UK Heat Transfer Society to the person who gives the best presentation at a society forum.