Numerical investigation of heat transfer and flow resistance in tubes with flat plate, blunt edge, and airfoil turbulators

Abstract

This study examines the effects of three turbulator designs—flat plate, blunt edge, and airfoil—on a tube’s heat transfer and flow resistance across a range of Reynolds numbers (3595–19,776). The performance of each turbulator was assessed through detailed analysis of velocity distributions at 33% and 66% of the blade length, cross-sectional velocity contours, Nusselt number (Nu), and friction factor (f). Results indicate that the flat plate turbulator produces the highest turbulence, resulting in maximum heat transfer and the greatest flow resistance. The blunt edge turbulator achieves a moderate balance, enhancing heat transfer with reduced turbulence compared to the flat plate. Meanwhile, the airfoil turbulator, with its streamlined profile, minimizes flow separation and disturbances, offering the lowest flow resistance but at the expense of heat transfer performance. This study underscores the trade-offs between heat transfer and flow resistance among the three turbulator designs, providing valuable insights for selecting the optimal turbulator based on specific application requirements.