Modeling the effect of helical baffles on the performance of shell and tube heat exchanger using CFD: (A case for Dashen Brewery Industry)

Abstract

One of the many kinds of heat exchangers that are used in industry is the Shell and Tube Heat Exchangers (STHE). According to estimates, more than 35 to 40 percent from heat exchangers are shell and tube systems and mostly constructed with segmental baffle and without baffle. Design of STHEs basically determines the heat transfer rate, and check for pressure drops of both shell and tube side fluid stream. For efficient heat transfer rate the pressure drop must be below allowable pressure drop which guarantee turbulence. One of the factors which causes pressure drop is baffle arrangement. Baffle is the component of STHE that used to support and prevent vibration of the tubes. However, it causes a turbulence in shell side fluid flow and increases the heat transfer coefficient. The main purpose of this study was to analysis the effect of helical baffle on the performance of STHE using CFD for Dashen Brewery Industry. In Modeling and simulation analysis of STHE constructed with segmental baffle, helical baffle and without baffle was developed using ANSYS 19.2 and comparative and validation analysis have been carried out. The result of simulation revels the heat transfer rate and pressure drop in both segmental, helical and without baffle STHE. In the comparative analysis, the performance of STHE constructed with helical baffle was 12.43 % higher than segmental baffle and 20.08 % without baffle. To increase the performance helical baffle STHE optimization analysis also investigated by orientation of baffle with helix angle of 8°, 10°and 12° and 8° have 1.13 % effective than 10°. Also, from the validation analysis the current study analysis have been valid and the previous study have supports to the current study analysis. As a final conclusion, the capacity of STHE developed with helical baffles have 90.5 % higher than the existing STHE in Dashen Brewery Industry. And the current study of STHE constructed with continuous helical baffle have better performance than the previous study of dis continuous helical baffle STHE by Asghar Ali Ghoto et.al. Furthermore, the industry have gotten much profitable with a simultaneous decreasing of heat exchanger area, inlet flow rates and pressure drop.