Baffle angle optimization of a typical shell and tube heat exchanger.

This article focuses on optimizing the baffle angles in a shell-and-tube heat exchanger (STHX) to enhance its thermal-hydraulic performance. Using a genetic algorithm (GA) combined with computational fluid dynamics (CFD) simulations and the realizable k-ε turbulence model, six optimal baffle angles were identified (315°, 195°, 80°, 340°, 250°, and 95°) for a common STHX model with six baffles and a 36% baffle cut. The optimized configuration (STHX-BOM) demonstrated improved heat transfer rates—up to 25.9% higher Nusselt numbers—and increased performance evaluation criteria (PEC) by 5.5% to 19.5% across flow rates of 0.5–2.0 kg/s, compared to the conventional staggered baffle arrangement. Enhanced flow mixing and increased interaction with tube walls were observed in the optimized model, although this also led to a moderate rise in pressure drop due to higher friction. The study suggests that strategic baffle angle optimization can significantly improve heat exchanger efficiency, with potential energy savings in industrial applications.