Thermal Performance Optimization of Shell and Tube Heat Exchangers Using Simulation Based Design Enhancements

Shell-and-tube heat exchangers are critical components in petrochemical processing, where efficient thermal exchange directly impacts energy consumption and product quality. This study investigates the thermal performance of a legacy heat exchanger used for naphtha cooling, employing Aspen HYSYS v14 and the Exchanger Design and Rating (EDR) module to simulate and optimize heat transfer characteristics. By varying tube length, baffle spacing, and flow rates, the study identifies configurations that enhance heat duty by up to 18% while maintaining acceptable pressure drops. The optimized design demonstrates improved temperature profiles, reduced fouling risk, and enhanced energy recovery, offering a scalable retrofit strategy for industrial heat exchangers.