Evaluating turbulence models for accurate thermo-fluid simulation in sthe with combined tube bundles

Year 2025, Volume: 9 Issue: 2, 258 - 271

Sara Sahrane , Slimane Niou

https://doi.org/10.31127/tuje.1546393

Abstract

Shell and tube heat exchangers are widely used for their thermal efficiency, and their performance is heavily influenced by the turbulence regime, which is primarily turbulent due to the complex geometry involved. This study evaluates the impact of three turbulence models—k-ε, k-ω, and realizable k-ε—on shell and tube heat exchangers with circular, 90° elliptical, and combined tube configurations, including line-line, random, and elliptical 90°-circular combinations. Using COMSOL Multiphysics software, we simulate thermofluidic flows and compare the results for each turbulence model and tube geometry. The results show that the k-ω model is the most effective for simple geometries, providing reliable and consistent outcomes, while the realizable k-ε model exhibits the lowest pressure drop, making it particularly suitable for configurations with varying mass flow rates and more complex geometries. The choice of different tube bundle combinations can significantly impact the overall thermal and hydraulic performance of the heat exchanger. For combined configurations, the k-ε model provides the best heat transfer performance, particularly in the STHE-E90°_C combination, where the strategic placement of circular tubes in the center and near the shell has a significant effect on optimizing both heat transfer efficiency and pressure losses. This study offers valuable insights for optimizing the design and performance of shell and tube heat exchangers, ultimately contributing to more efficient thermal systems.

Keywords

Shell and tube, heat exchanger, Turbulence models, tube configurations, Thermofluidic flows

Supporting Institution

LTSE, Energy Systems Technology Laboratory

Project Number

1

Thanks

The authors express their deep gratitude to the Mechanics of Materials and Plant Maintenance Research Laboratory (LR3MI) for providing the COMSOL Multiphysics software license, which significantly facilitated this work. Partial support for this research was provided by the Algerian Ministry of Higher Education and Scientific Research through the PRFU Project, code A11N01EP23022022002 (2022).

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