Optimized Design of Shell and Tube Heat Exchanger with Segmental Baffles

Heat exchangers are the apparatus which is widely used in various industries. They transmit heat among two or more fluid streams. Theoretical analysis done by Kern’s method has been done on Shell and tube heat exchanger with segmental baffle and then experimented in CFD to check Heat Transfer rate and pressure drop with varying number of baffles which is 6, 8 and 10, and by keeping all the rest of parameters constant. It is found that as the number of baffles increase heat transfer rate increases also pressure drop is increases significantly. To optimize model in next step, CFD analysis is has been done by varying baffle cut to 25%, 35% and 45% by keeping same number of baffles which found best in heat transfer rate in earlier Kern’s method. Other parameters like velocity, temperature, pressure and baffle numbers are kept constant. Results obtained from numerical solution are analysed extensively to get the effect of baffle cut on heat transfer rate and pressure drop on shell side. The pressing need of the heat exchanger industry, the tradeoff optimization between the pressure drop and the heat transfer coefficient has been studied to provide an idea to get effects of the change in two parameters, namely, baffle spacing and baffle cut simultaneously and observe how these two will affect the performance of an STHX. An attempt to find the optimum geometric configuration has been carried out with number of baffles. Increasing baffles for same length of shell and baffle cut increases from 25% to 35%, heat transfer rate increases. It is beneficial in elucidating that a higher heat transfer coefficient can be obtained for fewer baffles when coupled with the appropriate baffle cut. So selection of correct optimized shell and tube heat exchanger. The work is carried out for copper tube bundles and steel shell. So optimization of baffle cut with correct number of baffles and reduction in pressure drop studied with CFD tool.