Thermo-hydraulic efficiency enhancing: Optimized ladder fold baffle structure with cam and circle tube bundle

In this article, the design and thermo-hydraulic efficiency of a shell and tube heat exchanger (STHE) having ladder fold baffle equipped by two configurations with pore and without pore considering two types of tube bundles, cam and circular, are investigated numerically. Three-dimensional STHE is simulated employing the Solid Works Flow Simulation software. A numerical approach is performed for different values of mass flow rate from 0.5 to 2 kg/s, baffle height of 0, 20, and 40, and baffle pitch of 85.7, 60, and 46.15. STHE pressure drop, heat transfer, and efficiency evaluation coefficient (EEC) for different arrangements have been performed to study the STHE fluid flow and heat transfer. Obtained results for a ladder fold baffle and two studied types of tube bundles, cam, and circle, are provided, and thermo-hydraulic performance is compared with the current baffle structure. Based on the obtained results, an increase of 12.2% and 17.4% in pressure drop with increasing baffle height from 0 to 20 mm and from 20 to 40 mm was observed for circular tube bundles without pores, respectively. Related values for the case with pore are 14% and 14%. These values for the cam tube bundle are 12% and 15% without pores and 3% and 9% with pores. In addition, at an angle of 0, 20, and 40° in the case without pore, the EEC factor increased by 2.31%, 15.67%, and 15.47% compared to the case with pore for the cam tube bundle. The perforated ladder fold baffle showed the best performance with pitch and height of 85.7 mm and 40 mm, respectively.