Research on Adjoint Shape Optimization of Shell-And-Tube Heat Exchangers in Petroleum Transportation Systems

This study proposes a design method based on adjoint shape optimization to enhance the heat transfer efficiency of shell-and-tube heat exchangers in oil and gas transportation systems. The primary focus of this work is the design optimization of shell-and-tube heat exchangers through geometric optimization. By simplifying the complex three-dimensional shell-and-tube heat exchanger into a pseudo-three-dimensional reduced-order model, two-dimensional adjoint shape optimization analyses were conducted under unidirectional symmetry about the x-axis and bidirectional symmetry in the x- and y-axes, respectively. The optimized two-dimensional models exhibited a significant increase in the average outlet temperature. Furthermore, the optimized two-dimensional shapes were extruded and reconstructed into three-dimensional models for validation. The results demonstrate that the average air outlet temperature of the three-dimensional models increased by 5.35 K and 3.07 K compared to the original design. Flow field analysis revealed that the heat transfer was improved, since the optimized pipeline layout enhances flow separation and turbulent mixing, leading to a more uniform temperature distribution. This study validates the effectiveness of the adjoint shape optimization method in improving the performance of shell-and-tube heat exchangers.