This project investigates an innovative method for improving heat transfer efficiency in thermal systems through a newly developed multi-twisted blade turbulator (MTBT). Using advanced computational fluid dynamics (CFD) simulations, the research team designed a unique geometry that generates both swirling and radial fluid motion within a heated tube, thereby enhancing energy transport without adding mechanical complexity.
By systematically varying key parameters—namely the number of blades (4–10), the twist ratio (0.25–1), and the blade width (1–4 mm)—the study identified an optimal configuration of six blades, a twist ratio of 0.75, and a blade width of 3 mm. This combination achieved a performance evaluation criterion (PEC) of 2.8, representing an improvement of up to 273 per cent in heat transfer compared to a smooth tube, while maintaining a manageable pressure drop.
The findings are particularly relevant to the nuclear energy sector, where efficient heat removal and reliable cooling are vital for both performance and safety. In nuclear applications such as reactor cooling circuits, heat exchangers, and steam generators, the MTBT design could enable more compact, efficient, and inherently safer thermal management. Its passive nature and suitability for low-cost fabrication via 3D printing make it a strong candidate for both retrofitting existing systems and integration into next-generation reactor designs, including small modular reactors (SMRs) and fusion heat recovery systems.
Beyond nuclear applications, the MTBT concept offers promise for broader use in heating, ventilation and air conditioning (HVAC), energy conversion, and industrial cooling systems. Future developments may explore coupling the design with nanofluids or applying machine learning-based optimisation to achieve real-time adaptive thermal performance, contributing to more sustainable and efficient energy systems.