Finite Element Method Optimized Thermal Analysis of Heat Exchanger

Efficient heat exchangers are essential for thermal systems in industries ranging from power generation to chemical processing. This study presents a Finite Element Method (FEM) investigation of a shell-and-tube heat exchanger to evaluate temperature distribution, velocity flow patterns, and heat transfer performance. The 3D geometry was developed using CATIA and imported into ANSYS Workbench for simulation. Fine meshing was applied to improve computational accuracy, and steadystate thermal and fluid flow analysis was performed under defined inlet and outlet boundary conditions. Results indicate a minimum temperature of 303.71 K and a maximum of 321.68 K, with velocity ranging from 0.00417 m/s to 0.48556 m/s, showing smooth thermal gradients and laminar flow. The temperature contours reveal effective heat transfer from hot to cold regions, while velocity distributions highlight areas of flow deceleration, particularly near bends and expansion zones. The study confirms that FEM is a reliable tool for predicting heat exchanger performance, enabling design optimization, accurate material selection, and improved operational efficiency. Comparative analysis with literature demonstrates that the designed heat exchanger maintains thermal and hydraulic performance within acceptable limits. Recommendations include further optimization of tube arrangement, flow rate modulation, and validation through experimental studies. The findings provide a basis for future research on enhancing heat exchanger efficiency using advanced materials and hybrid designs