CFD-BASED COMPARATIVE ANALYSIS OF TUBE GEOMETRY AND BAFFLE DESIGN ON SHELL-AND-TUBE HEAT EXCHANGER PERFORMANCE USING SOLIDWORKS

Abstract

Shell-and-tube heat exchangers (STHEs) continue to dominate industrial applications because of their durability and adaptability across a wide range of operating conditions. As the push for higher energy efficiency intensifies, the use of Computational Fluid Dynamics (CFD) has become increasingly valuable for enhancing exchanger designs, supplementing and surpassing conventional analytical techniques. In this research, a comparative evaluation was carried out between two tube geometries—circular and square—in combination with two baffle arrangements: the traditional segmental type and the disk-and-doughnut design. Simulations were performed using SolidWorks Flow Simulation to assess steady-state thermal performance, focusing on outlet temperatures for both the shell-side and tube-side fluids. The ε–NTU method was then applied to determine exchanger effectiveness. The results indicate that the circular tube paired with a segmental baffle yielded the best performance (ε = 0.824), while the square tube with a disk-and-doughnut baffle produced a lower yet acceptable efficiency (ε = 0.752). Overall, the findings confirm that the interaction between tube geometry and baffle configuration plays a decisive role in the thermal characteristics of STHEs, emphasizing the need for their combined optimization in future designs.