Comparative CFD evaluation of turbulators for enhanced heat transfer in a double pipe counter-flow heat exchanger

Abstract

This study evaluates five turbulator configurations - twisted tape, corrugated tube, conical ring, dimpled tube, and a hybrid design (conical ring + twisted tape) - in a double pipe counter-flow heat exchanger using CFD simulations. The goal is to compare their impact on heat transfer efficiency and pressure loss. The results show that the hybrid turbulator offers the highest thermal performance but also leads to the highest-pressure loss, highlighting the trade-offs engineers must consider when optimizing heat exchanger performance