Effects of baffles and springs in shell and multi-tube heat exchangers: Comparative approach

Shell and multi-tube heat exchangers (SMTHX) are widely used in various industries such as power generation, chemical processing, and refrigeration due to their high efficiency and flexibility. Improving heat transfer within an SMTHX is critical for enhancing overall performance and efficiency. This study investigates the comparative effectiveness of using baffles versus spring wires to enhance heat transfer in SMTHXs. Both experimental and numerical analyses were conducted over a Reynolds number range of 8500–12500, focusing on key parameters such as the Nusselt number, pressure drop, and exergy efficiency. The experiments were performed with a variable cold water flow rate on the shell side and a constant flow rate on the tube side. The numerical model was validated against experimental results. The findings reveal that the Nusselt number increases to 62 with baffles and to 65.5 with spring inserts, representing improvements of 1.54 and 1.61 times, respectively, compared to a plain tube under identical conditions. While the pressure drop for baffles is significantly higher than for spring inserts, the springs show a pressure drop that is 87 % of that observed with baffles. Additionally, exergy efficiency is superior with spring inserts. These results demonstrate that spring inserts are more effective than segmental baffles in enhancing heat transfer in SMTHXs. The study provides valuable insights into the mechanisms of heat and fluid flow, supported by visualizations of velocity, temperature, and pressure contours and streamlines.