Computational analysis of single-shell-pass shell-and-tube heat exchangers with novel curved baffles and various tube layouts

Segmental and helical baffle designs for shell and tube heat exchangers (STHE) are generally used in industrial processing while curved baffles can be considered within the shell with various tube layouts to improve the shell-side fluid direction and increase heat transfer rate (heat transfer coefficient) and hydraulic (pressure drops) efficiencies. Therefore, the objective of this study was to evaluate the STHE performance by using novel curved baffle designs and tube layouts for heat transfer and hydraulic enhancements.

For this purpose, a computational approach was applied in an industrial scale STHE geometry, and curved baffles with their radii up to 1000 mm were considered in baffle arrangement configurations with different tube layouts. The computational model was validated with respect to the results of empirical approach and experimental studies, and the validated model was used to determine the effects of baffles numbers and their placement with a curved radius on thermal and hydraulic efficiency. It was demonstrated that the use of novel curved baffles resulted in enhanced heat transfer with lower pressure drops. Optimal curved radius was also determined for baffle placement configurations. While the helical baffles are preferred in designing the STHEs, curved baffles are also possible to use as an alternative choice with their installation and manufacturing flexibilities.