Numerical and experimental analysis on shell side thermo-hydraulic performance of shell and tube heat exchanger with continuous helical FRP baffles

The present work deals with the numerical and experimental investigation of heat and fluid flow in shell and tube heat exchanger with continuous helical baffles on shell side. Seven helix angles, namely 10°, 19°, 21°, 25°, 30°, 38°, and 50° are investigated numerically by modeling a full length continuous helical baffled shell-and-tube heat exchanger for different mass flow rates and inlet temperature conditions. Results revealed that the larger helix angles (30°, 38° and 50°) adds to lower heat transfer and lower pressure drop, and smaller helix angles (10°, 19°and 21°) resulted in higher heat transfer as well as higher pressure drop. The experiments were carried out on shell and tube heat exchanger for helical baffles with 25° helix angle and results were compared with segmental baffles. New baffle material, FRP (Fiber Reinforced Plastic) is introduced on the shell side of the proposed heat exchanger. For material comparison between FRP and stainless steel, the deviation of heat transfer coefficient is 8-10%, which can serve as a potential replacement for conventional baffle material, thereby reducing the capital and operating cost of the tubular heat exchanger.