HOW DO TURBULATORS WORK?

The efficiency of tubular heat exchangers can be improved either by optimizing its geometry and dimensions or by using heat transfer enhancement techniques. A key passive heat transfer technique in tubular heat exchangers is distorting a laminar flow by creating turbulence with the use of turbulator inserts within the tube. These turbulators come in a diverse range of geometries depending on, amongst others, the flow and temperature conditions.

Turbulator working principle

WORKING PRINCIPLE

In tubular heat exchanger systems heat transfer occurs at the tube wall. A common problem in tubular heat exchangers is the development of a thermal boundary layer due to flow stagnation of the heating medium (gas or liquid) near the tube wall. This thermal boundary layer restricts the convective heat transfer around the tube wall considerably. By increasing the turbulence intensity, turbulators reduce the development of this thermal boundary layer and create greater contact of the heating medium with the tube wall. Hereby the heat transfer coefficient of the heat exchanger increases substantially due to reduced exhaust losses.

THE PERFORMANCE OF JD TURBULATORS

The graph below demonstrates the effect of the application of our turbulators on heat transfer improvement of tubular heat exchangers. Our measuring results of flue gas flowing trough a 2 meter-long heat exchanger pipe show that with turbulators the heat transfer coefficient becomes nearly three times greater than in a smooth pipe. In practice this means that with the use of turbulators the length of the heat exchanger tubes can be reduced up to 50% compared to a smooth pipe without turbulators.

THE BENEFITS

THE BENEFITS OF JD TURBULATORS

  

  • Significant increase in heat transfer with low resistance. An increase in efficiency of upto 18% is achievable with the use of our turbulators.
  • More compact and lightweigth design: The length of the fire tubes can be reduced to between 35% and 50% of the smooth pipe length when turbulators are used.
  • Cleaning the fluepipes of biomass boilers – Scale deposits lead to a loss of efficiency of upto -0,05% per boiler cycle. Cleaning of the heat exchanger tubes is essential to restore maximal system performance.

THE BENEFITS OF ENERGY EFFICIENCY

Why is improving the energy efficiency of your appliance important?

  • Financial savings – boilers that operate more efficiently have lower operating costs because of fuel savings. Often the paybacktime of our turbulators is less then  1 year.
  • Reduced carbon footprint – by generating less energy, fuel emissions will be lower. energy-efficient heat exchangers contribute to achieving emission targets for CO2 and NOx emissions.
  • Environmental legislation/norms– appliances which operate energy-efficient will find it easier to comply with the tightening environmental regulations/norms. That means improved market share and productivity.

HOW DO TURBULATORS WORK?

The efficiency of tubular heat exchangers can be improved either by optimizing its geometry and dimensions or by using heat transfer enhancement techniques. A key passive heat transfer technique in tubular heat exchangers is distorting a laminar flow by creating turbulence with the use of turbulator inserts within ube. These turbulators come in a diverse range of geometries depending on, amongst others, the flow and temperature conditions.

WORKING PRINCIPLE

In tubular heat exchanger systems heat transfer occurs at the tube wall. A common problem in tubular heat exchangers is the development of a thermal boundary layer due to flow stagnation of the heating medium (gas or liquid) near the tube wall. This thermal boundary layer restricts the convective heat transfer around the tube wall considerably. By increasing the turbulence intensity, turbulators reduce the development of this thermal boundary layer and create greater contact of the heating medium with the tube wall. Hereby the heat transfer coefficient of the heat exchanger increases substantially due to reduced exhaust losses.

Turbulator working principle

THE PERFORMANCE OF JD TURBULATORS

The graph below demonstrates the effect of the application of our turbulators on heat transfer improvement of tubular heat exchangers. Our measuring results of flue gas flowing trough a 2 meter-long heat exchanger pipe show that with turbulators the heat transfer coefficient becomes nearly three times greater than in a smooth pipe. In practice this means that with the use of turbulators the length of the heat exchanger tubes can be reduced up to 50% compared to a smooth pipe without turbulators.