Heat Transfer Optimization in Baffled Heat Exchangers

Baffled heat exchangers leverage internal baffles to direct fluid flows, enhancing turbulence and improving heat transfer across shell-and-tube arrangements. Optimization efforts centre on maximising the overall heat transfer coefficient while balancing pressure drop and pumping power. Strategies include passive modifications—baffle geometry, spacing and orientation—and active techniques such as fluid augmentation with nanofluids. Recent computational and experimental advances employ high-resolution CFD, parametric studies and multi-objective algorithms to identify designs that offer superior thermal–hydraulic performance. These developments are critical in reducing energy consumption across power generation, chemical processing and HVAC systems, supporting global decarbonisation and industrial efficiency targets.

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Heat Transfer Optimization in Baffled Heat Exchangers publication trend

The graph below shows the total number of articles in heat transfer optimization in baffled heat exchangers across all publications each year (not limited to Nature Index journals).

Technical terms

Baffle: An internal plate or vane in a heat exchanger shell that directs fluid flow to enhance turbulence and heat transfer.

Nusselt number: A dimensionless measure of convective heat transfer relative to conduction across a fluid boundary.

Reynolds number: A dimensionless quantity describing the ratio of inertial to viscous forces in a fluid flow.

Pressure drop: The difference in fluid pressure between inlet and outlet, reflecting hydraulic resistance.

Computational fluid dynamics (CFD): A numerical method for simulating fluid flow and heat transfer within complex geometries.

References

1. A comprehensive review of methods of heat transfer enhancement in shell and tube heat exchangers. Journal of Thermal Analysis and Calorimetry (2023).
2. Multi-objective optimization of helical baffles in the shell-and-tube heat exchanger by computational fluid dynamics and genetic algorithm. Energy Reports (2022).
3. CFD and PIV Investigation of a Liquid Flow Maldistribution across a Tube Bundle in the Shell-and-Tube Heat Exchanger with Segmental Baffles. Energies (2020).
4. Numerical Investigation and Optimization on Shell Side Performance of A Shell and Tube Heat Exchanger with Inclined Trefoil-Hole Baffles. Energies (2019).
5. Experimental and Numerical Investigation on Non-Newtonian Nanofluids Flowing in Shell Side of Helical Baffled Heat Exchanger Combined with Elliptic Tubes. Applied Sciences (2017).