Heat Transfer Analysis with Graphical Examination for Different Materials of Tubes of Surface Condenser

This study presents a thermal analysis of a shell and tube-type surface condenser used for converting steam into condensate. A CAD model was developed using Solid Works, and simulations were conducted in ANSYS to examine heat transfer characteristics across different tube materials: Copper alloy, Aluminum alloy, and Structural Steel. Results indicated that copper alloy tubes delivered the highest heat flux—35.103 W/mm² in initial conditions and 11.381 W/mm² in final conditions—alongside the lowest deformation (3.6589 mm) and a relatively low maximum equivalent stress of 975.69 MPs. In comparison, aluminum alloy and structural steel showed inferior thermal performance. These findings establish copper alloy as the optimal tube material for efficient condenser design, improving heat transfer and structural integrity.