Numerical Investigation of Conjugate Convective Heat Transfer and Structural Behavior of a Shell and Tube Heat Exchanger using Finite Element Method
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Abstract
This study presents the effects of varying steam temperature levels passing through a shell-and-tube heat exchanger on the stress distribution and thermal expansion of the material, using the Finite Element Method (FEM) to identify potential weak points during actual operation. The results aim to support precautionary measures in the manufacturing process. The internal flow is modeled as turbulent. The influence of steam or more generally, the working fluid temperature on material behavior is analyzed. Under thermal equilibrium between the steam and the material surface, increasing the temperature at the elliptical head of the heat exchanger from 200°C to 300°C leads to increases in Von Mises stress and material expansion by 380 MPa and 0.45 mm, respectively. The study systematically presents both stress and thermal expansion outcomes under the influence of fluid temperature, addressing what is known as a conjugate convective heat transfer problem. The accuracy of the mathematical model is validated by comparing the outlet temperatures of the fluid on both the shell and tube sides, as well as the pressure drop within the tube, against benchmark models from related research. The numerical results show good agreement, with outlet temperature differences of 3.7% on the shell side and 1.4% on the tube side, and a pressure drop discrepancy of 5%. Furthermore, this research provides a foundation for future investigations into other fluid-induced effects on heat exchanger, such as erosion and corrosion within the equipment.
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