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shell and tube heat exchanger with staggered baffles (Paper CFD Validation)

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The simulation is based on a reference article “Numerical analysis and optimization on shell-side performances of shell and tube heat exchanger with staggered baffles” and its results are compared and validated with the results in the article.

This ANSYS Fluent project includes CFD simulation files and a training movie.

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Description

Paper description

The present problem simulates the water flow inside a shell and tube heat exchanger. The simulation is based on a reference article “Numerical analysis and optimization on shell-side performances of shell and tube heat exchanger with staggered baffles” and its results are compared and validated with the results in the article. In this project, the water with temperature-dependent properties will enter the computational domain with an initial temperature of 293K and a velocity of 3.19m/s (referring to 4kg/s mass flow rate) and passes through staggered baffles and over the heated tubes with a temperature equal to 353K.

Shell and Tube Geometry & Mesh

The geometry of this project is designed in ANSYS design modeler and consists of several hot tubes and staggered baffles and is meshed in ANSYS meshing software. The mesh type used for this geometry is unstructured and the element number is 8031842.

shell and tube shell and tube

Shell and Tube CFD Simulation Settings

The critical assumptions considered in this project are:

  • Simulation is done using a pressure-based solver.
  • The present simulation and its results are considered steady and do not change as a function of time.
  • The effect of gravity has not been taken into account.

The applied settings are summarized in the following table.

 
(shell and tube) Models
Viscous model k-epsilon
k-epsilon model Realizable
near-wall treatment standard wall function
Energy on
(shell and tube) Boundary conditions
Inlet Velocity inlet
Inlet2 3.19 m/s
Temperature 293 K
Outlet outflow
Walls Stationary wall
Tube walls Temperature 353 K
Shell wall Heat flux 0 W/m2
(shell and tube) Solution Methods
Pressure-velocity coupling   coupled
Spatial discretization Pressure standard
Momentum second order upwind
Energy second order upwind
turbulent kinetic energy second order upwind
turbulent dissipation rate second order upwind
Initialization
Initialization method   Hybrid

Paper Validation Results (Shell and Tube)

At the end of this simulation, the present work results are compared with results obtained by the paper. The diagram in Figure 18 was used for this purpose, which shows the changes in pressure drop over different mass flow rates for different staggered angles (beta). It should also be noted that we have validated the results for beta angle = 60 degrees and mass flow rate = 4 Kg/s.

  Paper’s results CFD results error
Pressure drop 200000 Pa 189384.758 5.3%

All files, including Geometry, Mesh, Case & Data, are available in Simulation File. By the way, the Training File presents how to solve the problem and extract all desired results.

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