A CFD Analysis of Shell and Tube Heat Exchanger with Segmental Baffles

Abstract

A single-pass shell-and-tube heat exchanger with segmental baffles has been analyzed numerically. The study focuses on the crucial aspects of heattransferandflowpatterns, which arenumericallyinvestigatedbyvarying the number of baffles. The standard k-e model is employed to solve the problem, and numerical simulations are conducted for three cases of baffle spacing with a square bundle of tubes.Using a commercialcomputational fluid dynamics (CFD) solver, the study obtains numerical solutions by solving the three-dimensional continuity, momentum, energy, and turbulence (k-?) equations. The number of baffles is variable, while other parameters such as velocity, temperature, pressure, andbaffle cut are kept constant. The results obtained from the computational analysis are analyzed to understand the effect of several baffles on the heat transfer rate and pressure drop on the shell side.

Introduction

Heat exchangers are vital in industries for temperature control and phase changes of fluids, with their performance assessed mainly by heat transfer efficiency and pressure drop. Various studies have investigated how design factors such as baffle type, spacing, cut, and inclination affect these parameters. For example, using trefoil hole baffles or adjusting baffle spacing can improve heat transfer but may increase pressure drop, requiring an optimal balance.

This study employs computational fluid dynamics (CFD) simulations using ANSYS Fluent to analyze a shell-and-tube heat exchanger (STHE) with segmental baffles, using liquid Helium for its superior cryogenic properties. The heat exchanger components are made from stainless steel (shell), copper (tubes), and aluminum (baffles). Different baffle configurations (3, 4, and 5 baffles) were tested to evaluate their impact on heat transfer and pressure drop.

Results show that increasing the number of baffles enhances turbulence, fluid mixing, and heat transfer efficiency, as reflected by progressively lower outlet temperatures (80 K for 3 baffles, 78 K for 4, and 75 K for 5). However, higher baffle counts also increase pressure drops. Velocity profiles confirmed the development of zigzag flow patterns and recirculation zones that promote heat transfer.

The study confirms that optimizing baffle design is crucial to maximizing heat exchanger efficiency while managing pressure losses, with CFD providing valuable insight into thermal and fluid dynamic behavior.

Conclusion

The research has successfully evaluated the transient thermal behavior of a heat exchanger-type shell-and-tube (STHE) with segmental baffles using CFD simulations in ANSYS. The simulations demonstrated that the heat exchanger\'s performance was heavily dependent on the number and positioning of baffles; specifically, one arrangement was recommended that achieved a tradeoff between enhancing thermal performance and improving flow distribution. Helium exhibits a significantly higher temperature increase for all baffle arrangements compared to air/water. The growth is much more pronounced for Helium, while for air and water, it is moderate. Helium reaches 900K with 5 baffles, while air and water remain below 350K, proving that Helium is a better heat transfer fluid. Validation: The simulation results were validated against experimental and theoretical data with a reasonable degree of accuracy for the measured temperature profiles and heat transfer rates. The simulated numerical results were consistent with the correlations confirmed in the literature, providing accuracy to the model and reliable simulation data for the experimental component.

References

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Copyright

Copyright © 2025 Musaddiq Mohammad, K. V. Sharma, M. T. Naik. This is an open access article distributed under the Creative Commons Attribution License, which permits unrestricted use, distribution, and reproduction in any medium, provided the original work is properly cited.