Working Principle

The twisted tube is formed by plastically deforming straight tubes into a continuous helical shape. This geometry induces secondary flow and turbulence in both the tube-side and shell-side fluids, which helps:

• Disrupt laminar boundary layers, enhancing the convective heat transfer coefficient;

• Eliminate flow dead zones, ensuring uniform distribution of shell-side fluids;

• Reduce fouling due to increased shear stress and self-cleaning effect.

Unlike conventional shell-and-tube heat exchangers that require baffles to direct shell-side flow, twisted tube designs achieve enhanced flow performance naturally through their geometry, reducing pressure losses and mechanical complexity.

Structural Features

• Helically twisted tubes with enhanced turbulence-promoting surfaces;

• Self-supporting tube bundle structure eliminates the need for baffles;

• Compact design, offering a higher heat transfer area per unit volume;

• Wide material compatibility, including carbon steel, stainless steel (304/316L), duplex steel, titanium, and other corrosion-resistant alloys;

• Available in fixed tube sheet, U-tube, and floating head designs, suitable for various cleaning and maintenance requirements.

Key Technical Advantages

Typical Applications

Twisted tube heat exchangers are ideal for high-performance thermal exchange where fouling, efficiency, and pressure drop are concerns. Key industrial applications include:

• Steam condensers in power plants;

• Crude oil and gas cooling systems in refineries;

• Oil-to-oil and oil-to-water heat exchangers in chemical processes;

• Waste heat recovery units for boilers and turbines;

• Amine and glycol cooling systems;

• Viscous fluid exchangers in polymer, fertilizer, and petrochemical plants.

Performance and Operational Benefits

• Improved heat transfer performance in both laminar and turbulent flow regimes;

• Lower fouling rate, resulting in reduced cleaning frequency and longer uptime;

• Eliminated or reduced need for internal baffles, simplifying mechanical design;

• Reduced operating costs due to energy savings and minimized maintenance;

• Increased reliability and longevity, even in corrosive and high-pressure environments;

• Effective thermal performance under compact spatial constraints.

Summary

The Twisted Tube Heat Exchanger represents a next-generation solution for industries requiring compact, efficient, and low-maintenance heat transfer equipment. By enhancing turbulence and minimizing fouling through a simple geometric innovation, it delivers superior thermal performance, extended service life, and reduced total cost of ownership compared to traditional heat exchanger types.