Design of metal foam baffle to enhance the thermal-hydraulic performance of shell and tube heat exchanger

Abstract

Solid baffles are widely used in shell and tube heat exchanger (STHX), while the highly increased flow resistance and dead zones remain serious drawbacks in the applications. To address this issue, metal foam baffle is proposed in this study to replace solid baffle. The numerical model with considering the thermal non-equilibrium between fluid and foam baffles was established. Laminar flow is assumed in the foam baffles region and the realizable k-ε turbulence model is assumed in the open region. Effects of porosity, pore density, thickness and number of foam baffle (N) on the performance were examined. Results show the foam baffles always lead to lower pressure drop of STHX compared to the solid baffles. Compared to five 2 mm thick solid baffles, five 6 mm thick metal baffles with the porosity of 0.80, 0.85 and 0.90 results higher outlet temperature at the pore density greater than 80, 120 and 160 PPI, respectively. The metal foam baffle leads to higher outlet water temperature compared with solid baffles at the baffle number N ≤ 7. The foam baffles with optimum pore parameters reduced the pressure drop by 12.9 % and increase the outlet and inlet temperature difference by 31.0 % compared to the solid baffles.