Journal of Design for Sustainable and Environment, Vol. 4 No. 1 (2022) p.

9-14

JDSE Journal of Design for Sustainable and Environment

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e-ISSN : 2682-7441

Simulation of Shell and Tube Heat Exchanger: Influence of

the Lower Flows and the Baffles on a Fluid Dynamics
Chow Kah Teck1,a, Kwong Wei Ming1,b, Muhammad Syafiq Shaiful Anuar1,c , Haiqal Haziq Nor Sham 1,d, Allison
Soundrapaman5,e, Djamal Hissein Didane2,f*, Bukhari Manshoor2,g

1Faculty of Mechanical and Manufacturing Engineering, Universiti Tun Hussein Onn Malaysia,
Parit Raja, Batu Pahat, 86400, MALAYSIA
2Center for Energy and Industrial Environment Studies (CEIES), Universiti Tun Hussein Onn Malaysia,
86400, Batu Pahat, Johor, MALAYSIA

*Corresponding Author

Email: aCD190234@siswa.uthm.edu.my, bCD190196@siswa.uthm.edu.my, cCD190227@siswa.uthm.edu.my,

dCD190206@siswa.uthm.edu.my, eCD190212@siswa.uthm.edu.my, fdjamal@uthm.edu.my, gbukhari@uthm.edu.my

Received 15 November 2022;
Accepted 26 January 2022;
Available online 01 April 2022
Abstract: This study proposes the numerical reproduction of the flow of water in a shell-and-tube
heat exchanger 2:1 according to the CLASS C TEMA standard (for moderate operation conditions,
with commercial application). With baffles made of aluminium and copper tube for the flow of cold
fluid, the shell is made of acrylic, and thermal analysis efficiencies with regard to the presence or
absence of the baffles, that is, to analyse the efficiency with only the tubes and the shell and soon
after the analysis with tubes and baffles. The use of these equipment on an industrial size offers
creative processing solutions reflecting the processes efficiency, providing considerable savings and
reduced cost, supporting the company success, and therefore presenting chances, social
responsibility, which are the pillars of sustainability. Heat exchangers are a frequently used
equipment on an industrial and commercial scale. Following the design parameters and boundary
conditions, the fluids' behaviour in the shell and the tube were investigated using computational
fluid dynamics (CFD) using the programme ANSYS CFX 15.0 for the creation of this study. The
results were compared to Excel worksheets that were made using the equations and correlations that
already existed. The Reynold number used in this study is 𝑅𝑒 = 2000 ~ 1000000. The Reynold
number affects the simulation result where the higher the Reynold number, the higher the average
heat flux and Nusselt number. On the other hand, this study finds out that the most suitable model
for numerical simulation based on the SST turbulence model since the results obtained from the
SST model is having the least deviation.

Keywords: Shell and Tube Heat Exchanger, Ansys CFD tool, Baffles

1. Introduction
Heat transfer is the transmission of thermal energy
induced by a temperature differential in a medium, which may
occur by conduction, convection, or irradiation. The heat
exchange process is any action or set of operations conducted
on one or more materials to alter their energy, composition,
size, or any other physicochemical attributes. The apparatus
for the heat exchange process between two fluids with distinct
temperature gradients and separated by a solid wall is known
as a heat exchanger. This process happens in several technical
applications. In a heat exchanger, heat transfer typically
occurs by convection in each fluid and conduction through the
wall separating the two fluids. This study references many
kinds of heat exchangers, including concentric tube heat
exchangers, parallel flow, counter-current, and cross flow,
with fins for both mixed and unmixed fluids, as well as shell
and tube heat exchangers with baffles [1]. Heat exchangers are
very significant equipment in any global situation due to their
widespread usage on an industrial scale, since they are
responsible for the biggest energy needs as well as being
process equipment responsible for all industrial processes,
such as footwear, beverage, and other sectors. They are used a
lot because they are easy to make and can be made from many
kinds of materials. Furthermore, the operational temperature

*Corresponding author: djamal@uthm.edu.my

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 Chow, K. et al., Journal of Design for Sustainable and Environment, Vol. 4 No. 1 (2022) p. 9-14
and pressure have no limitations. Various research is being
conducted to find methods to improve the efficiency of these
machines, enhance their capacity for heat exchange, and
minimize the investment necessary for their construction [2],
[3]. However, its usage is not limited to the industrial
environment, as it is present in people's everyday life in many
forms such as freezers, heaters, electric showers, and air
conditioners, among others, pushing even more researchers to
develop sustainable projects that must be efficient,
inexpensive, and less costly. The performance of these
exchangers may be improved by installing baffles in the shell
to guide the flow of fluid through the tubes on the shell side of
a heat exchanger to recover geothermal brine heat for further
power production. Based on the results, the heat exchanger
can be used in the model Organic Rankine Cycle power plant's
evaporator [4]. Moreover, it was determined that when the
angle of inclination grew from 0 to 60 degrees, the heat
transfer coefficient value increased because of an increase in
the swirl.
Furthermore, a shell and tube heat exchanger is a type of
heat exchanger that consists of a series of tubes that are
enclosed within a larger, cylindrical shell. One fluid flows
through the tubes while another fluid flows around the outside
of the tubes, either in the shell or in a separate chamber. The
heat is transferred between the two fluids through the walls of
the tubes, allowing the fluids to exchange heat without coming
into direct contact with each other. These heat exchangers are
commonly used in a variety of industrial and commercial
applications, including power generation, HVAC, and process
manufacturing [5]. A shell and tube heat exchanger is
commonly used in a variety of industrial and commercial
applications, such as power generation, HVAC systems,
process manufacturing, marine and shipbuilding, the food and
beverage industry, pharmaceuticals and other industries like
oil and gas, paper, pulp and many more also use shell and tube
heat exchangers in various processes. Baffles are internal
partitions or plates that are placed inside a shell and tube heat
exchanger to control the flow of fluids and to increase the
efficiency of heat transfer. They are typically made of metal
and are attached to the interior of the shell. Baffles are placed
in the shell perpendicular to the flow of the fluid in order to
create a series of small channels for the fluid to flow through.
This slows down the fluid and increases the time it is in contact
with the tubes, which improves heat transfer. Baffles also help
to reduce fluid velocity and prevent erosion of the tube walls.
Additionally, the use of the baffles increases the turbulence of
the fluid, which improves the heat transfer coefficient by
increasing the heat transfer surface area and thus increases the
efficiency of the heat exchanger [6]. The primary purpose of
baffles in a shell and tube heat exchanger is to increase the
efficiency of heat transfer between the two fluids. Baffles are
used to control the flow of the fluid in the shell, creating a
series of small channels for the fluid to flow through. This
slows down the fluid and increases the time it is in contact with
the tubes, which improves heat transfer [5]. Baffles also help
to reduce the fluid velocity and prevent erosion of the tube
walls, create a better fluid distribution across the tubes and
improve the heat transfer coefficient by increasing the heat
transfer surface area and increasing the turbulence of the fluid,
which also improves the heat transfer coefficient, improve the
temperature distribution across the heat exchanger by
reducing the temperature difference between the inlet and
outlet of the fluid, support the tubes and prevent the tubes from
vibrating, buckling, or collapsing due to fluid pressure.
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Overall, the use of baffles in a shell and tube heat exchanger
improves the performance of the heat exchanger, making it
more efficient and reliable [7].
Furthermore, there are many types of baffles used in shell
and tube heat exchangers. They are used in shell and tube heat
exchangers, including the double-segmental baffles which are
the most common type of baffles used in shell and tube heat
exchangers. They are made of two segments that are attached
to the shell with a gap in between them. This gap allows the
fluid to flow around the segments, creating a small channel for
the fluid to flow through and slowing down the fluid to
improve heat transfer. While the single-segmental baffles are
similar to double-segmental baffles but are made of a single
segment that is attached to the shell. This type of baffle is less
common than double-segmental baffles but can be used when
space is limited. There are also chevron baffles which are V-
shaped baffles that are used to direct the flow of the fluid in a
specific direction. They are used to prevent the fluid from
flowing directly across the tubes, which can reduce the
efficiency of heat transfer. The cut-and-alternate baffles are a
type of double-segmental baffles in which the gap between the
two segments is smaller than the width of the tube. The tubes
are arranged alternately on either side of the baffle. This type
of baffle increases the turbulence of the fluid, which improves
the heat transfer coefficient. The rod baffles are cylindrical
rods that are used to support the tubes and prevent them from
vibrating, buckling, or collapsing due to fluid pressure. They
are generally used in high-pressure or high-temperature
applications. There are also others like spiral baffles, split flow
baffles, etc. The choice of the type of baffle to use in a shell
and tube heat exchanger depends on the specific application,
the type and properties of the fluids, and the size and design
of the heat exchanger.
Therefore, the purpose of this research is to simulate the
water flow in a 2:1 shell-tube heat exchanger using numerical
methods. The initial study focuses on the differences in mass
flow rates in the shell and tube, as well as their influence on
heat exchange. Later, baffles are introduced to assess their
impact on the heat exchange efficiency. Using the Transfer
Unit Number (NUT) approach, the findings are compared to
the heat exchanger design to provide confidence in the applied
mathematical modeling.
2. Materials and Methods
The framework for the simulation of shell and tube heat
exchangers for the influence of lower flows and the baffles on
a fluid dynamics analysis using Computational Fluid
Dynamics (CFD) with ANSYS is explained in this section.
The various stages that are used in the process are explained
in detail. Writing a CFD code to provide an answer for each
new fluid glide case could be time-consuming and punishing.
As a result, standard industrial CFD codes such as ANSYS
CFX are used as they can provide user-friendly graphical user
interfaces (GUIs) to allow the user to make use of a built-in
code with a slew of troubleshooting features to provide a
solution for issues such as fluid flow, heat transfer, and so on.
The process of creating a solution to a fluid problem using a
standard CFD code is defined in three stages. Pre-processing,
processing and post-processing.
2.1 Model Creation, Meshing and Simulation Setup
The first step in the pre-processor stage is to define a
suitable geometry for analyzing the fluid flow problem.
Geometry can be defined by replicating a known geometry
using computer-aided design (CAD). After geometry has been
 Journal of Design for Sustainable and Environment, Vol. 4 No. 1 (2022) p. 9-14
created, a suitable mesh can be constructed. A mesh is a
discretized extent that has been divided into smaller volumes
or elements. Once a plausible mesh has been created,
additional known quantities of the fluid, such as density,
viscosity, and turbulent portions, are defined. Boundary
conditions, such as temperature, strain, velocity profile, and so
on, are applied to cell faces inside the shape of a flux adjoining
an inlet/exit or wall. Figure 1 shows the geometry of Case 1
Domain Geometry without baffles before meshing and Figure
2 shows the inner view for Domain geometry without baffles
before meshing.
Fig. 1 - Dimensions of domain geometry without baffles
Fig. 2 - Dimensions of baffles
Fig. 3 - Domain geometry without baffles before meshing
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Fig. 4 - Inner view for domain geometry without baffles
before meshing
Fig. 5 - Domain geometry without baffles after meshing
Figure 5 illustrates the mesh type of the hex dominant
method and sizing into 0.00003m. In the finite volume
method, the mesh considers points that form a set of volumes
known as cells. Finite element methods employ sub-volumes
known as elements, which contain nodes where variables are
defined. For each element, the values of the dependent
variables, such as temperature, pressure, velocity, and so on,
will be described. The mesh quality has a significant impact
on the quality of the CFD result. In the finite volume method,
the mesh considers points that form a set of volumes known
as cells. Finite element methods employ sub-volumes known
as elements, which contain nodes where variables are defined.
Figure 4 below shows the details of meshing and CFD
simulations of domain geometry without baffles.
The solver is a calculation technique that results in the
solution of the transport equations. There are three distinct
streams of numerical solution techniques which are the finite
difference method, finite element technique and finite volume
technique. In this study, we need to apply boundary conditions
to analyze it. Hence, in this study, there are three cases which
are shown below.
a) Case 1
In case 1, was the shell and tube heat exchanger without
baffles (for pressure). The simulation model temperature for
tubes was 27.1°C and the shell was 39.6°C. Meanwhile, the
SST temperature for the tube was 27°C and the shell was 28.27
°C.
b) Case 2
In case 2, was the shell and tube heat exchanger without
baffles. The simulation model temperature for tubes was
32.7°C and the shell was 78.5°C. Meanwhile, the SST
temperature for the tube was 27.02°C and the shell was
34.53°C.
 Chow, K. et al., Journal of Design for Sustainable and Environment, Vol. 4 No. 1 (2022) p. 9-14

c) Case 3 3. Results and Discussion

In case 1, was the shell and tube heat exchanger with 3.1 Grid Independence Test for SST Model
baffles. The simulation model temperature for tubes was A Grid independence test is done on the SST model to
45.3°C and the shell was 77.9°C. Meanwhile, the SST determine that the results are not affected by the grid. Grid
temperature for the tube was 26.99 °C and the shell was 27°C. independence test also called GIT is the test that numerical
The physical properties of the water used in the present simulations are carried out by using different meshing setup
work are such that the water viscosity is 8.899 E−4 Pa*s and results in different element numbers. The allowable deviation
the density: is 997 kg/m3. percentage for GIT is only 5%. Four different meshing setups
are used in this study for the GIT which is written as Set 1 to
2.2 Governing Equations and Calculation Parameters Set 4 and has 682339, 716294, 736184 and 833366 elements
Navier-Stokes equations are the governing equations of respectively.
Computational Fluid Dynamics. It is based on the Table 1 shows the results obtained for the GIT on the SST
conservation law of the physical properties of the fluid. The model. All the sets with the largest element numbers which are
principle of conservational law is the change of properties, for set 4 are used as the reference to calculate the deviation
example, mass, energy, and momentum, in an object is percentage. Based on the results obtained, case 1 is having all
decided by the input and output. The permanent equations deviations below 5% and which means that the results for case
considered in the mathematical modeling were the 1 are quite accurate. Then, case 2 has half of the deviation
conservation of linear momentum (Equation (1)), mass higher than 5% which makes the results less reliable on it.
(Equation (2)) and energy (Equation (3)). Moreover, case 3 only has a value of deviation that is more
than 5% which is at the tube outlet of set 3. However, the
𝛻 ∙ 𝜌𝑈⨂𝑈 + ∆𝜌 − ∆{𝜇 ∙ [∆𝑈 + (∆𝑈)𝑇 ]} (1) (1) deviation for it is too high which is 14.75% which affects the
reliability of results. Thus, it can be summarized that the SST
model is the most suitable model for the study and the meshing
(2) setup will not affect the accuracy of the result for case 1.
However, the deviation for it is too high which is 14.75%
(3) which affects the reliability of results. Thus, it can be
summarized that the SST model is the most suitable model for
the study and the meshing setup will not affect the accuracy of
the result for case 1.
Using the NUT method, the maximum thermal exchange
value, Qmax, is obtained from the input temperature values of Table 1 - Grid independence test for SST model
the fluids, and the Mean Logarithm of Temperature
Cases Element Outlet Temperature, %
Differences (MLDT) method allows us to find the value of the
T (°𝐶) deviation
Real thermal exchange, Q, using the inlet and outlet
temperatures. The effectiveness, ε, is given by: Case 1 Set 1 Tube 27 0
(682339) Shell 28.27 4.66
(4) Set 2 Tube 27.01 0.04
(716294) Shell 27.13 0.44
Set 3 Tube 27.01 0.04
(736184) Shell 72.06 0.19
Set 4 Tube 27 -
The relative error, E, is given from the Vexp expected (833366) Shell 27.01 -
value and Vobt values obtained by: Case 2 Set 1 Tube 27.02 0.07
(682339) Shell 34.53 19.40
(5) Set 2 Tube 27 0
(716294) Shell 27.23 5.84
Set 3 Tube 27 0
After that, the average heat flux at the shell surface and (736184) Shell 27.26 5.74
its Nusselt numbers are calculated with different Reynold Set 4 Tube 27 -
numbers which include Reynold numbers of 2000, 5000, (833366) Shell 28.92 -
100000, 500000, and 1000000. The average heat flux and Case 3 Set 1 Tube 26.99 3.23
Nussult number are given as shown in Euqation 6 and (682339) Shell 27 0
Euqation 7. Set 2 Tube 27.01 3.16
(716294) Shell 27 0
𝑑𝑇(𝑥) Set 3 Tube 32 14.74
𝑄̇ = −𝑘 (6) (736184) Shell 27 0
dx
Set 4 Tube 27.89 -
ℎ𝐿
𝑁𝑢 = (7) (833366) Shell 27 -
k

Where, 3.2 Validation

Q ̇ = Heat Flux This study starts with the validation of the numerical
T = Temperature simulation based on the study of Sebastião et al (2017) [8].
k = Thermal conductivity The validation of this study is done between three turbulence
h = Heat transfer coefficient models with the simulation study model. The turbulence
L = Characteristics length model selected is the SST k-omega model. Table 2 shows the

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 Journal of Design for Sustainable and Environment, Vol. 4 No. 1 (2022) p. 9-14

validation done on the SST model. It shows that the lowest contours for all cases are shown in Figure 8 and Figure 9.
deviation is at case 1 tube outlet which is only 2.18% while Based on these figures the overall pressure of the shell body
the highest deviation is at case 3 shell outlet which is 24.58%. with the highest value is case 3 which is 9.31e+11 while case
Most of the deviation is below 15% and there is only one case 1 and case 2 have the same pressure of 6.08e+5 at the shell
that exceeds 15% of deviation which is at the shell outlet of body. At the same time, case 3 has the lowest temperature
case 3. The most suitable model for numerical simulation within the shell body. By comparing the initial temperature, it
based on the study of Sebastião et al (2017) [8] is the SST is observed that the model with baffles which is case 3 has the
model since the results obtained from the SST model is having highest thermal exchange efficiency. Even though the models
the least deviation compared to the RNG and Realizable without baffles are able to conduct the thermal exchange
model. Plus, the numerical simulation done by the study of process, the value of thermal exchange efficiency is lower than
Sebastião et al is inaccurate since most of the deviation or error the model with baffles. Thus, baffle presence significantly
percentage is at a high value. increases the thermal exchange efficiency. Furthermore, the
average heat flux at the shell surface and its Nusselt number
Table 2 - Validation with previous results are calculated with different Reynold numbers including
Reynold numbers of 2000, 5000, 100000, 500000, and
Case Outlet Experimenta SST %
s s l Model (Temperatur deviatio 1000000.
(Temperatur e, °𝐶) n
e, °𝐶) 7000
Case Tube 25.6 27 5.47 6000

Nusselt Number
1 Shell 28.9 28.27 2.18 5000
Case Tube 28.6 27.02 5.52
4000
2 Shell 35.8 34.53 3.55
Case Tube 28.6 26.99 5.63 3000
3 Shell 35.8 27 24.58 2000
1000
3.3 Average Heat Flux 0
2000 5000 100 000 500 000 1 000
Figure 6 shows the graph of the average heat flux for the
000
SST model with different Reynolds numbers at the shell Reynold Number
surface. The value of average heat flux increases while the
Reynold number increases. Although the graph is also
showing an increment on it, the value of heat flux of Reynold's Fig. 7 - Nusselt Number with Different Reynold
numbers 2000 to 5000 is just a slight change. Thus, it means Number
that the changes in Reynold number will affect the value of the
average heat flux for the SST model after a specific value of Cases Pressure Contour
Reynold number. Case 1

6 4.929
5
4
Heat Flux

3 2.39
2
0.749
1 0.013 0.177 0.176
0
2000 5000 100 500 1 000 Case 2
000 000 000
Reynold Number

Fig. 6 - Average heat flux for SST model with different

Reynold Number

3.4 Nusselt Number

Figure 7 shows the graph of the value of the Nusselt
number at different values of the Reynolds number. The graph
shows that the SST model has the highest Nusselt number at
6639.16 with the Reynold number of 1000000. On the other
side, the Realizable model has the lowest Nusselt number at
169.42 with the Reynold number of 2000. The entire graphs
pattern for all models shows an increment in the Nusselt
number while the Reynold number increases. Thus, the
increase in Reynold's number will affect the changes in
Nusselt number. The pressure contours and temperature

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 Chow, K. et al., Journal of Design for Sustainable and Environment, Vol. 4 No. 1 (2022) p. 9-14

Case 3 and temperatures. There are few things can be concluded from
this study:
i. Mathematical modeling satisfactorily captures the
phenomenon of flow in shell-and-tube heat
exchangers.
ii. Physically speaking, current lines, pressure, and
temperature fields behave as they should.
iii. Higher pressure is the result of higher mass flow
rates.
iv. The thermal exchange efficiency is greatly
improved by the baffles.
v. The gradient in temperature along the exchanger
increased as the temperature at the shell entrance
rose.
Fig. 8 - Pressure contours
Acknowledgement
Cases Temperature Contour The authors would like to acknowledge the financial
Case 1 support provided by the Universiti Tun Hussein Onn Malaysia
through the H919 grant.

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Fig. 9 - Temperature contours

4. Conclusion
The design of shell and tube heat exchangers is complex
thus requiring good knowledge regarding its variables mainly
regarding their velocity, but this study is related to flow rates

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