A heat exchanger is a device that facilitates the transfer of heat from one medium to another. Typically this process is deployed between two fluids of different temperatures. Still, air-to-air heat exchangers are becoming an increasingly popular means of regulating conditions whilst reducing energy emissions and costs.

A balanced air-to-air heat system sees the exchanger recover and store heat energy from extracted air to heat the air being drawn and processed from outside. Such a mechanical exchanger usually sits between two separate ducts — an air supply air fan and an extract air fan. The fresh, filtered air is then either heated or cooled according to need and returned to the space.

Heat exchangers are central to the quest for energy efficiency across countless industries, products, and machines. They are deployed to perform heating and cooling processes including aeronautical engineering and HVAC design, and in environments such as grand-scale power stations.

In short: heat exchangers play a major role in creating more efficient systems.

Maximising the efficiency of heat exchangers is also paramount, and can hinge on optimising the airflow and air velocity within them. That’s where we come in. In this post, we explore ways of improving heat exchanger efficiency and delve into the crucial role of airflow and air velocity sensors in their design, maintenance, and development.

Enhanced efficiency and sensor benefits

There are several steps that businesses and manufacturers can take to optimise the efficiency of their heat exchangers. The benefits of doing so include reduced energy consumption, lower operating costs, and improved environmental credentials.

Design elements to enhance performance

Optimising the design of heat exchangers is essential for maximising their efficiency. From selecting the right heat exchanger through to incorporating and calibrating sensor technology, there are several ways to build efficiency into the exchanger at the very start of its operational life.

Sizing and selection

There are dozens of heat exchangers on the market, spanning a breadth of fluid-based and air-to-air technology. Selecting the right heat exchanger based on the specific application is pivotal. Considering its function, thermal requirements and more will stand engineers and operators in good stead to draw the most from the exchanger in practice.

Similarly, sizing the heat exchanger correctly per the heat load and air or fluid flow rates will eliminate the chance of compatibility and functionality issues.

Thermal design and insulation

When developing, designing or calibrating heat exchangers, it’s key to consider the best thermal principles for each specific use case. In this instance, consider the benefits and drawbacks of counter-flow or crossflow configurations as against something like parallel flow. Choosing materials with high thermal conductivity will also help enhance exchanger efficiency.

Once developers have tuned the design of the heat exchanger in response to both thermal principles and material, insulating the heat exchanger will help minimise heat loss to the surroundings, especially in applications with elevated temperatures.

Incorporating sensor technology

Airflow and air velocity sensors play a crucial role in improving energy exchanger efficiency. Engineers can fine-tune exchanger designs for optimal performance by integrating sensors that detect and relay important data to the overarching system.

Leveraging data from airflow sensors, designers can optimise the layout of fins, tubes, and other components within the exchanger to minimise pressure drops and improve heat transfer efficiency. Similarly, air velocity sensors enable precise control of fan speeds, ensuring that airflow remains within the desired range for optimal heat exchange.

Flusso’s sensors empower exchanger designers and engineers to continually optimise flow patterns and fine-tune fan performance.

Maintenance and ongoing efficiency

Design and implementation are only as effective as the regular maintenance that follows. Over time — regardless of the nature of the heat exchanger — dust, debris, and other contaminants can accumulate within the system, impeding airflow and reducing overall efficiency. Taking maintenance seriously is a core way to improve heat exchanger efficiency.

Upkeep schedule and temperature control

Manufacturers and broader teams invariably benefit from clear product maintenance schedules, spanning site visits, exchanger inspections, cleaning, repairs, and even part replacements should they be required. This level of diligence is key to ensuring heat exchangers within applications are running to their engineered capabilities.

As part of this, temperature control strategies and monitoring can be implemented to maintain desired temperature differentials across the heat exchange, mitigating the risk of excessive energy consumption and ensuring optimal control.

Distributing flow and leveraging sensors

Effectively distributing flow across the exchanger system will help to maintain its efficiency. Uneven flow can lead to hotspots and poor performance, so optimising air flow velocities within design limits can prevent losses in efficiency.

Evidently, sensor technology that delivers accurate and timely data to the heat exchanger control systems will be invaluable during maintenance. Using airflow and air velocity sensors gives operators real-time insights into system performance, including prompt detection of any anomalies or blockages. These readings will help engineers understand heat exchanger operation based on load conditions and other external factors, thus maximising efficiency and preventing unnecessary energy usage during partial loads or periods of downtime.

Heat exchanger operators will also be able to regularly analyse performance data from the flow sensors to identify trends and opportunities for future design.

Flusso’s airflow sensors are renowned for their precision and reliability. Heat exchanger operators that deploy our sensors will be able to see clear, accurate flow data even in challenging environments. Further standout features, such as integration with a wireless solution and IoT compatability, enable enhanced heat exchanger design and maintenance.

Here at Flusso, we are constantly refining our flow-sensing technology to meet the needs of different industries, including the various applications in which heat exchangers play a vital role.

Heat exchanger efficiency into the future

Optimising airflow and air velocity is key to achieving the goal of increased efficiency in heat exchanger systems. By leveraging Flusso’s advanced flow sensor technology, operators and engineers can monitor and control airflow with unparalleled precision, leading to significant energy savings and improved performance.

In addition to initial design considerations, routine maintenance schedules, and other methods to improve heat exchanger efficiency, we are confident Flusso’s sensors have a major role to play in the long-term.

Curious to know what we have planned? Get in touch!