Improving the design of a shell-and-tube heat exchanger

Shell-and-tube heat exchangers remain key elements in various industries due to their reliability and versatility. However, their operation is associated with problems such as hydraulic shocks caused by condensate accumulation in the intertube space. The article considers unstable operation of a heat exchanger designed for a chemical plant according to an individual project, which provides for a horizontal arrangement of the device due to technical requirements. The option proposed by the supplier is based on a classic horizontal heat exchanger with a floating head according to the design of AO «VNIINefteMash». The design of transverse partitions with horizontal cutouts leads to condensate accumulation and hydraulic shocks. The novelty of the proposed solution lies in changing the orientation of the cutouts in the partitions from horizontal to vertical, which ensures natural condensate drainage and eliminates the cause of hydraulic shocks. Modeling in KOMPAS-Flow software confirmed the reliability of the device: the absence of stagnant zones in the modernized design, and calculations in HTRI X-Changer Suite confirmed its energy efficiency and performance. The relevance of the solution is due to the prevalence of horizontal shell-and-tube devices operating with steam-water mixtures. The proposed approach can be adapted for similar devices, which will increase their reliability, reduce vibration loads and extend the service life. The research results confirm the effectiveness of the synergy of design and hydrodynamic optimization methods, which corresponds to modern trends in the design of heat exchange equipment. In the future, it is planned to test the modernized design in production and extend the solution to other types of heat exchangers, which will help improve the safety and efficiency of industrial processes.