Session: Research Posters

Paper Number: 172551

Parametric Optimization and Comparative Performance Analysis of Shell-and-Tube and Tubular Heat Exchangers for Enhanced Thermal Effectiveness 

Heat exchangers are foundational components in thermal energy systems, widely used across numerous sectors such as petrochemical processing, power generation, food manufacturing, and chemical industries. Among the various types of heat exchangers, shell-and-tube and tubular configurations are particularly prominent due to their mechanical durability, ease of maintenance, and adaptability to a wide range of thermal loads and flow conditions. This study presents a comparative performance analysis and parametric optimization of two liquid-to-liquid heat exchanger systems namely, the HT33X Shell-and-Tube Heat Exchanger (Armfield Inc.) and the HT36X Extended Tubular Heat Exchanger (Armfield, Inc.). The overarching goal of this work is to investigate the heat transfer and fluid flow behavior in each system, identify key design parameters influencing performance, and use those findings to inform the development of an optimized, high-effectiveness hybrid heat exchanger suitable for real-world industrial applications.

The first phase of the research focuses on the HT33X shell-and-tube system. This unit comprises seven 6.35 mm inner tubes enclosed within a 44.45 mm diameter shell and supported by six semicircular baffles. The overall heat transfer surface area is approximately 20,000 mm², with a heat transfer length of 144 mm. A countercurrent configuration was used in all tests, with cold water flowing through the shell side and hot water through the tubes in the opposite direction. Experimental measurements were conducted under varying hot fluid velocities, while maintaining controlled inlet temperatures and flow rates for both fluids. The results indicate that increasing hot fluid velocity leads to an approximate 7% improvement in thermal effectiveness. However, the peak experimental effectiveness observed remained relatively low at 0.22, highlighting limitations within the baseline design.

To support and validate the experimental findings, computational simulations were conducted using ANSYS Fluent, employing the finite volume method to solve the governing equations of heat and fluid flow. The CFD model, which closely mirrored the physical configuration and boundary conditions of the experimental setup, predicted a slightly higher effectiveness of 0.28. The discrepancy of roughly 27% between the simulation and experimental data is attributed to practical factors that are difficult to fully replicate in a numerical model—such as heat loss to the environment, flow maldistribution, minor fouling within the tubes, and pressure stabilization issues.

In light of these findings, the study is actively exploring several design modifications aimed at improving thermal effectiveness and overall performance. One of the key areas of focus is the geometry and arrangement of baffles within the shell. Diagonally arranged or inclined baffles are being evaluated for their ability to enhance shell-side turbulence and disrupt stagnant flow regions, which are known to reduce heat transfer efficiency. Another proposed modification involves equipping the U-shaped tubes with radially placed straight fins. This approach aims to increase the heat transfer surface area by approximately 300%, with the expectation that this expansion will significantly raise the exchanger’s effectiveness. Preliminary simulations of these proposed designs suggest the potential to more than double the baseline effectiveness, reaching values above 0.50.

While the shell-and-tube configuration provides valuable insight, the study also includes a parallel investigation of the HT36X Extended Tubular Heat Exchanger to serve as a benchmark and source of complementary design strategies. The HT36X model consists of four segmented concentric tubes arranged in a coaxial fashion, with multiple temperature measurement points along both the hot and cold fluid paths. This design allows for a detailed examination of temperature gradients, pressure drops, and flow behavior under classical countercurrent flow conditions. Unlike the HT33X, which is primarily characterized by baffle-induced cross-flow in the shell, the HT36X offers a more uniform axial flow with well-defined thermal profiles.

By comparing the experimental and simulated performance of both systems—evaluating parameters such as Nusselt number, Reynolds number, pressure drop, and outlet temperature differentials—this study aims to distill the strengths and weaknesses of each configuration. These insights are critical to informing the development of a novel heat exchanger design that combines the enhanced turbulence and compact form of the shell-and-tube model with the efficient axial flow and segmented measurement precision of the tubular model.

The research is currently ongoing, with further simulations and experiments planned to refine the proposed enhancements and assess their impact under a wider range of operating conditions. Integrated use of ANSYS Fluent and MATLAB enables iterative testing of parametric changes, with emphasis on identifying optimal combinations of geometric and operational variables. Ultimately, this work aims to deliver a high-performance heat exchanger design that meets the demanding thermal efficiency and reliability standards of modern industrial applications.

Presenting Author: Maya Panta Woodrow Wilson High School, Beckley, WV

Presenting Author Biography: Maya Panta is a rising senior at Woodrow Wilson High School in Beckley, WV, where she serves as the president of the Science Club. Deeply passionate about science and engineering, Maya has received multiple awards at state-level science and engineering fairs for her innovative work. Most recently, she presented her research on “Heat Exchanger and Its Optimization” at the West Virginia Academy of Science, where she earned first place in the undergraduate category—a remarkable achievement for a high school student. In spring 2025, she also represented her work on national and global platforms, presenting at both the International Science and Engineering Fair (ISEF) and the Junior Science and Humanities Symposium (JSHS). Maya’s hard work, creativity, and commitment to scientific inquiry have rightfully earned her a place among the most promising young researchers in the country.

Authors:

Yogendra Panta West Virginia University Institute of Technology (WVU Tech)
Maya Panta Woodrow Wilson High School, Beckley, WV