THERMIX, novel adaptable heat exchanger inserts for ultra-efficient heat transfer in viscous complex fluids

As we move to a decarbonised world, the focus on energy efficiency in the process industry becomes ever greater. This industry alone uses at least 11% of the UK's heating energy demand with the focus now narrowing on making every step of the process as efficient as possible to reduce energy use and carbon dioxide emissions. The process industry largely uses heat exchangers to heat and cool process fluids or to recover energy. CALGAVIN specialises in the research, design, specification and manufacturing of in-tube heat transfer enhancement devices for process exchangers which it sells worldwide.
In-tube inserts are in general metal structures that are installed into the tubes and manipulate the fluid flow to improve the heat transfer between two fluids and that allow heat exchangers to be smaller, less expensive and more efficient. However, some fluids have properties that make them difficult to enhance. Such fluids can be highly viscous which gives them a thick, honey-like texture that severely inhibits the effectiveness of heat transfer. Other types of fluids are comparatively little studied, "complex" fluids that change how easily or otherwise they flow, depending on how much stress is applied to them. High viscosity and complex fluids are used in a huge variety of products including petrochemicals, plastics, polymers, paints/coatings, food products and fast-moving consumer goods.
Currently insert geometries, established for use in mixing fluids inside tubes, are also used for enhancing heat exchanger performance but not having been optimised for this use, they carry a high penalty in terms of large pumping power needed relative to the limited heat transfer enhancement gained. CALGAVIN will use the now available, state-of-the-art technologies for measurement, in conjunction with the University of Birmingham, to further develop insert technology made specially for high viscous and complex flows. Each process has varying characteristics, requiring unique designs and for which clients require process guarantees. The resulting joint research, development and testing programme will lead to CALGAVIN expanding its range of unique products and technical solutions to satisfy its growing list of processors worldwide.