Numerical Analysis and Optimization of Shell-and-Tube Heat Exchangers Using CFD: A Comparative Study with Traditional Correlation-Based Methods

Abstract

This thesis presents a comprehensive performance evaluation of a shell-and-tube heat exchanger using analytical methods—Kern and Bell-Delaware correlations—and Computational Fluid Dynamics (CFD). The study investigates the influence of mass flow rate and number of baffles on heat transfer characteristics and pressure drop. Results show that increasing the mass flow rate from 0.5 to 2.0 kg/s significantly enhances the heat transfer coefficient due to increased turbulence, but also results in higher pressure losses. Among the analytical methods, the Kern method consistently underestimated both heat transfer and pressure drop, particularly at higher flow

rates and baffle counts, with deviations exceeding 50% compared to CFD. The Bell- Delaware method demonstrated better agreement with CFD, as it accounts for shell- side effects such as bypassing and leakage; however, it still underpredicted pressure

drops under high-resistance flow conditions.