Optimization Design Study on the Notch Angle of Baffles in Shell-and-Tube Heat Exchangers

Abstract Intubated heat exchangers are widely used in industry due to their excellent heat transfer performance and compact structure. The geometric parameters of baffles significantly influence both fluid dynamics and thermal performance. This study systematically investigates the effects of the cut angle in disc-and-doughnut baffles on flow characteristics and heat transfer performance through numerical simulation. The results demonstrate that reducing the cut angle enhances the heat transfer coefficient at the expense of increased pressure drop, while enlarging the angle diminishes both parameters. Based on computational fluid dynamics (CFD) analysis, an optimized design strategy is proposed to achieve enhanced thermal efficiency with reduced flow resistance. For applications prioritizing heat transfer capacity, a smaller cut angle is recommended. This research provides innovative perspectives for the optimal design of shell-and-tube heat exchangers and establishes a theoretical framework for geometric optimization of baffle structures.