Optimization of Counter Flow, Single Pass Shell & Tube Heat Exchanger Header Using CFD Analysis

Abstract

In this paper, a Computational Fluid Dynamic (CFD) Simulation of five different shell and tube heat exchanger (STHE) header geometries is performed. Geometrical designs are analyzed computationally through CFD analysis to find the optimized header geometry for using as heat exchanger header. The geometric models are analyzed for flow mal-distribution. The flow through the Header geometries is studied in details and the variation of various parameters including pressure distribution, velocity distribution and eddies formation is analyzed for five geometrical models. A comparison of these properties is developed in order to distinguish the best possible geometry. Comparison of results yielded that abrupt changes in the area of heat exchanger header gives rise to flow mal-distribution resulting in eddies formation as well as it results in non-uniform distribution of pressure and velocity across the header. This phenomenon can be controlled by uniformly varying the area of the header in such a way that flow separation is reduced. The results for the suggested header geometries yield up to 70% less flow turbulence in comparison to the geometries already in practice .The suggested geometries also possess better pressure and velocity distribution across the header length.