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Simulation of Shell-and-Tube Heat Exchanger Performance Using COMSOL

Shell-and-tube heat exchangers, commonly used in industries like oil refineries and nuclear power plants, facilitate heat exchange between water and air. The model considers design parameters, geometry, and boundary conditions to predict a temperature decrease of 75°C to 13°C across the exchanger. Results show an overall heat exchange coefficient of 5.9W/(m².K) and pressure drops of about 40 Pa for water and 13 Pa for air.

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Simulation of Shell-and-Tube Heat Exchanger Performance Using COMSOL

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  1. Shell-and-Tube Heat Exchanger COMSOL

  2. Background  Shell-and-tube heat exchangers are one of the most widely used type of heat exchanger in the processing industry. They are commonly found in oil refineries, nuclear power plants and other large-scale chemical processes  Two separate fluids at different temperatures flow through the heat exchanger: one through the tubes, the other in the shell surrounding the tubes  Several design parameters and operating conditions influence the optimal performance of a shell-and-tube heat exchanger

  3. Model Definition  Water flows through the tubes, and air circulates in the shell  Baffles are introduced to create a cross-flow and to increase the exchange surface  All walls are made of structural steel and modeled as shells in 3D  Heat transfer and turbulent flows physics are coupled Model geometry

  4. Model Definition  A symmetry is used to reduce the computational cost  The exterior walls are thermally insulated, while the interior walls allow heat exchange  Wall functions are used in addition to the k-εturbulence model Model boundary conditions

  5. Results  The water is guided through the tubes where it exchanges heat with the air  The temperature difference between air and water at their respective inlet is 75°C, which is reduced to about 13°C at their outlet  The overall heat exchange coefficient of this heat exchanger is 5.9W/(m².K) Streamlines in water and air domains. Colored by temperature

  6. Results The pressure drop is slightly lower than 40 Pa for water and about 13Pa for air Pressure evolution in the air and water domains between inlet and outlet

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