3D numerical simulation on shell-and-tube heat exchangers with middle-overlapped helical baffles and continuous baffles – Part I: Numerical model and results of whole heat exchanger with middle-overlapped helical baffles

In the present study, a 3D numerical simulation of a whole heat exchanger with middle-overlapped helical baffles is carried out by using commercial codes of GAMBIT 2.3 and FLEUNT 6.3. At first, the computational model and numerical method of the whole heat exchanger with middle-overlapped helical baffles is presented in detail, and parallel computation mode is adopted for the simulation of a whole heat exchanger with six cycles of the middle-overlapped helical baffles of 40° helical angle on a grid system of 13.5-million cells; second, the validation of the computational model is performed by comparing the total pressure drop and average Nusselt number of the whole heat exchanger with experimental data. Reasonably good agreement is obtained, and the reasons causing to the discrepancy are analyzed. The shell-side fluid pressure and temperature fields of the whole area are then presented. Finally the cycle average Nusselt number of different cycle in the heat exchanger are compared and it is found that within the accuracy allowed in engineering computation, periodic model for one cycle can be used to investigate the heat transfer and pressure drop characteristics for different heat exchanger to save computational source. The companion paper will provide details of simulation results using the periodic model for different helical angles and different structures of helical baffles.