Aarush Mehra
Independent Researcher
India
ABSTRACT
This manuscript explores the optimization of heat exchanger efficiency through the application of finite element analysis (FEA). Finite element models of shell-and-tube and plate heat exchanger configurations are developed using established pre-2018 methodologies. Parametric studies are conducted to assess the effects of geometric parameters, material properties, and operating conditions on thermal performance and pressure drop. Case studies demonstrate the optimization workflow, including mesh refinement, boundary condition specification, and validation against experimental data from literature published before 2018. The results reveal that optimizing baffle spacing, tube layout, and plate corrugation angle can enhance overall heat transfer coefficients by up to 20% while maintaining acceptable pressure drops. Conclusions emphasize the benefits of FEA-driven design in improving thermal efficiency and offer guidelines for engineers seeking to implement similar strategies using technologies and software available up to 2018.
KEYWORDS
Heat exchanger, Efficiency optimization, Finite element analysis, Shell-and-tube, Plate exchangers, Baffle design, Thermal performance
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