Three-Dimensional Modeling of a Helixchanger® Heat Exchanger Using CFD

Abstract

Detailed three-dimensional computational fluid dynamics (CFD) simulations have been performed to explore the performance of a helically baffled heat exchanger, commercially referred to as the Helixchanger ® heat exchanger. The CFD simulations employ the HEATX computer simulation program, which is designed for the simulation of shell-and-tube heat exchangers. The simulation accounts for the complex helical geometry of baffles, leakages, and nozzle entrance and exit. Three cases are presented that correspond to helix angles of 10°, 25°, and 40°, defined with respect to the radial axis. Inspection of the computed flows reveals distinct inner and outer regions, with the outer region showing a very desirable plug flow characteristic. The inner region, however, displays recirculation zones due to back mixing at the small helix angle, which suggests potential vibration problems but also creates a desirable temperature uniformity. A comparison with plug flow showed that the helically baffled heat exchanger had a fluid turn ratio of 0.64, 0.78, and 0.77 for the 10°, 25°, and 40° helix angles, indicating more overall plug-like flow for the higher helix angles. Computed pressure drops compare reasonably well with ABB Lummus Heat Transfer correlation results, although nozzle entrance and exit losses require further study.