Boosting Boiler Efficiency with Brock Angular Turbulators: A Case Study

In industrial settings, maximizing boiler efficiency is essential for reducing energy costs and improving sustainability. An independent study at Penn State University evaluated the impact of Brock Angular Turbulators on boiler performance. This post explores the findings and key takeaways, highlighting how turbulators can make a measurable difference in energy savings.

What Are Turbulators?

Turbulators are inserts placed inside boiler tubes to disrupt laminar gas flow, promoting more efficient heat transfer. By enhancing turbulence, they ensure that more heat energy is transferred from the hot gases to the water or steam inside the boiler tubes.

The Experiment: Testing in a 3-Pass Firetube Boiler Simulator

The Penn State study focused on the effect of Brock Angular Turbulators in a 3-pass firetube boiler simulator. Measurements were taken under two scenarios:

  1. Without turbulators – to establish baseline efficiency.

  2. With turbulators installed – placed in the last pass (third-pass tube), covering two-thirds of the tube length.

Key Results and Findings

  1. Efficiency Gain

    • Baseline (No Turbulators): 79.1% efficiency

    • With Turbulators: 85.1% efficiency
      Installing turbulators boosted the boiler's efficiency by 6.1%, demonstrating a significant improvement in energy utilization.

  2. Reduction in Stack Temperature

    • Baseline: 323°F

    • With Turbulators: 224°F
      On average, the study observed a 1% efficiency increase for every 17°F reduction in stack temperature. This indicates that better heat retention within the boiler translates directly into efficiency gains.

  3. Energy Savings Exceed Efficiency Gains

    • The study reported 7.72% energy savings, which exceeded the 6.1% increase in efficiency. This means for every 1% increase in efficiency, there was a 1.26% energy savings gain.

  4. Trade-off: Increased Pressure Drop
    While the benefits were clear, there was an increase in pressure drop due to the turbulators:

    • Baseline pressure drop: 0.44" WC

    • With turbulators: 2.24" WC
      This trade-off must be considered, as higher pressure drops may affect boiler performance in certain applications.

Why Energy Savings Matter

The study’s findings highlight how small efficiency improvements translate into significant energy savings. With 8,760 operating hours per year (assuming continuous use), businesses can achieve substantial cost savings through reduced fuel consumption. This means:

  • Lower operational costs

  • Faster return on investment for turbulator installation

Conclusion: A Simple Way to Increase Boiler Efficiency

This independent study demonstrates that Brock Angular Turbulators can significantly enhance boiler efficiency and energy savings. For businesses looking to improve energy efficiency and reduce operational costs, turbulators provide a quick, cost-effective solution with short payback periods.

However, it is essential to balance the increased efficiency with the added pressure drop. Ensuring optimal turbulator configuration is crucial to achieving the best results in real-world applications.

Take Action

If your business operates boilers, consider exploring how turbulators can enhance your system’s performance. With documented energy savings and quick payback times, Brock Angular Turbulators offer a simple way to improve efficiency and reduce operational costs.

By understanding how small changes can deliver meaningful savings, businesses can take steps toward a more energy-efficient future.

Click the link below to see our turbulator options

 

*Penn State University. (n.d.). Synopsis of independent testing: Brock Turbulators. Unpublished report.