Modeling and CFD analysis of shell-and-tube heat exchanger with helical baffles: performance evaluation through baffle pitch optimization
Abstract
This research presents a detailed computational assessment of a shell-and-tube heat exchanger equipped with helical baffles, emphasizing the influence of baffle pitch on the system’s overall thermal and hydraulic behavior. The primary aim was to enhance heat transfer capability while limiting pressure losses, which is an essential requirement for industrial sectors such as energy production, petrochemicals, refrigeration, and HVAC (Heating, Ventilation, and Air Conditioning) applications. The heat exchanger model was constructed in CATIA V5, and CFD (Computational Fluid Dynamics) simulations were performed in ANSYS Fluent 15.0 to analyze the impact of different baffle pitches (ranging from 26 to 50 mm) on shell-side performance parameters: pressure drop, temperature difference, and total heat transfer rate over a mass flow range between 0.1571 and 0.6284 kg/s. The computational results found a 38-mm baffle pitch as the most efficient configuration, yielding a maximum heat transfer rate of 14.9 kW and a temperature reduction of 8.4 °C, with a moderate pressure penalty. Visualization of the flow field confirmed the formation of stable swirling and crossflow zones that promote effective mixing without introducing excessive resistance. The study delivers a systematic CFD-based analysis covering a broad range of operating conditions and offers practical guidelines for perfecting industrial heat exchanger designs. The novelty of this work lies in its quantitative evaluation strategy, which decides the best configuration through balanced consideration of both thermal enhancement and fluid dynamic efficiency. In addition to conventional thermal and hydraulic parameters, the study introduces a thermal–hydraulic performance metric based on the heat transfer rate per unit pressure drop(Q/ΔP). This index provides an integrated measure of heat transfer effectiveness compared to pumping power. Analysis of this performance index further confirms that the 38 mm pitch delivers the highest thermal–hydraulic efficiency, confirming it as the best configuration across all tested operating conditions.