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<p>Designing high‑performance shell‑and‑tube heat exchangers (STHXs) for industrial applications requires coordinated control of flow structure, thermal transport, and hydraulic losses. In this study, an industrial‑scale STHX is systematically optimized by jointly controlling working‑fluid properties and internal geometry within a unified thermal–hydraulic framework. The analysis integrates Al<sub>2</sub>O<sub>3</sub>–water nanofluids (<i>ϕ</i> = 0–0.5&#xa0;vol.%), advanced tube‑side turbulence promoters (microfin and warped tape), shell‑side baffle‑cut ratios (15–35%), and tube‑pass configurations (1–4) using the validated HTRI Xchanger Suite. A fully parametric numerical investigation is conducted to resolve how each design variable contributes to heat‑transfer enhancement, pressure‑drop evolution, and outlet temperature behavior under realistic industrial operating conditions. Model predictions are confirmed through comparison with published industrial and experimental data, with deviations below 8–10% and numerical uncertainty within ± 2%. The results identify geometric modulation as the dominant enhancement mechanism and quantify the distinct roles of different turbulators. Microfin inserts increase the tube‑side heat‑transfer coefficient by 62–78% relative to plain tubes, exceeding the performance of warped tape inserts (54–68%) while maintaining approximately 13% lower pressure‑drop penalties. On the shell side, a 30% baffle cut consistently establishes the most favorable balance between cross‑flow impingement and bypass flow across all nanofluid concentrations. Thermal performance improves monotonically with nanoparticle concentration but reaches saturation beyond <i>ϕ</i> = 0.5&#xa0;vol.%. Increasing the tube‑pass number enhances heat transfer up to an optimum of three passes, after which additional passes mainly intensify hydraulic losses. The highest overall thermal–hydraulic performance index (THPI = 1.022) is achieved using a microfin turbulator combined with a 0.5&#xa0;vol.% nanofluid and a 30% baffle cut. The findings provide directly applicable design guidance for maximizing thermal efficiency while maintaining hydraulic feasibility in industrial STHXs.</p>

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Synergistic thermal–hydraulic and energy performance enhancement of shell‑and‑tube heat exchangers using Al2O3 nanofluids and advanced turbulence promoters

  • 期刊论文

  • 发表日期：

    2026年4月22日

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  • Shaikh Hasibul Majid,
  • A. K. Kareem,
  • Navruzbek Shavkatov,
  • K. D. V. Prasad,
  • T. Ramachandran,
  • Abhayveer Singh,
  • A. Karthikeyan,
  • Dhirendra Nath Thatoi,
  • Ali Shamel

摘要

Designing high‑performance shell‑and‑tube heat exchangers (STHXs) for industrial applications requires coordinated control of flow structure, thermal transport, and hydraulic losses. In this study, an industrial‑scale STHX is systematically optimized by jointly controlling working‑fluid properties and internal geometry within a unified thermal–hydraulic framework. The analysis integrates Al2O3–water nanofluids (ϕ = 0–0.5 vol.%), advanced tube‑side turbulence promoters (microfin and warped tape), shell‑side baffle‑cut ratios (15–35%), and tube‑pass configurations (1–4) using the validated HTRI Xchanger Suite. A fully parametric numerical investigation is conducted to resolve how each design variable contributes to heat‑transfer enhancement, pressure‑drop evolution, and outlet temperature behavior under realistic industrial operating conditions. Model predictions are confirmed through comparison with published industrial and experimental data, with deviations below 8–10% and numerical uncertainty within ± 2%. The results identify geometric modulation as the dominant enhancement mechanism and quantify the distinct roles of different turbulators. Microfin inserts increase the tube‑side heat‑transfer coefficient by 62–78% relative to plain tubes, exceeding the performance of warped tape inserts (54–68%) while maintaining approximately 13% lower pressure‑drop penalties. On the shell side, a 30% baffle cut consistently establishes the most favorable balance between cross‑flow impingement and bypass flow across all nanofluid concentrations. Thermal performance improves monotonically with nanoparticle concentration but reaches saturation beyond ϕ = 0.5 vol.%. Increasing the tube‑pass number enhances heat transfer up to an optimum of three passes, after which additional passes mainly intensify hydraulic losses. The highest overall thermal–hydraulic performance index (THPI = 1.022) is achieved using a microfin turbulator combined with a 0.5 vol.% nanofluid and a 30% baffle cut. The findings provide directly applicable design guidance for maximizing thermal efficiency while maintaining hydraulic feasibility in industrial STHXs.