Challenge
A heat exchanger has reached the end of its service life and is causing process disruptions. The load is so low that the flow is laminar. As a result, there is insufficient mixing, which leads to instability in the process. In fact, the heat exchanger is too large for the current operating conditions.
Approach
To improve the flow dynamics without having to replace the entire heat exchanger, a targeted modification was chosen: installing Pop‑A‑Plug® plugs in a portion of the tubes. This reduces both the heat exchange and flow-through surface area and results in an increased flow velocity, causing the flow to become turbulent again; which is essential for proper mixing and heat transfer.
Result
The adjustment leads to a direct improvement in process stability. By restoring turbulent flow, the medium mixes effectively again, without the need for a complete replacement of the heat exchanger.
Pop‑A‑Plug® plugs: a cost-effective and technically efficient solution that extends the lifespan of the installation and restores process reliability.
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