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Design and Optimization of Heat Exchanger Systems for Industrial Applications

Radius: Journal of Science and Technology

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Volume 2, Issue 1,  Article Number: 251006 (2025) 

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Mohammad Ashraf1,* | Neelesh Khare2

1Research Scholar, 2Assistant Professor

Department of Mechanical Engineering, School of Engineering & Technology, Shri Venkateshwara University, Gajraula, U.P.

*Corresponding Author: mdash00786@gmail.com

Received: 23 April 2025 | Revised: 30 April 2025

Accepted: 01 May 2025 | Published Online: 02 May 2025

DOI: https://doi.org/10.5281/zenodo.15327130

© 2025 The Authors, under a Creative Commons license, Published by Scholarly Publication

Abstract

The industrial processes of power generation alongside chemical manufacturing along with refrigeration and HVAC systems depend fundamentally on heat exchangers. The design quality of heat exchangers enables superior thermal performance, together with reduced operational expenses. The research analyzes the design approach for Shell & Tube Heat Exchangers (STHE) since these units remain popular because of their long service life and flexible application options. The paper presents an approach for practical design methodology which focuses on industries lacking sophisticated simulation capabilities. A basic approach for thermodynamic analysis and parameter estimation leads to spreadsheet-based manual optimizations for designs. The optimized heat exchanger design achieved a 9% increase in heat transfer efficiency and approximately 12% reduction in material usage. The main goal is to decrease energy waste and optimize heat transfer operations together with lowering production materials and expenses. A study demonstrates this method’s effectiveness because it boosts efficiency and decreases surface area requirements along with design time requirements. Basic tools enable meaningful improvements to be carried out in heat exchanger systems.

Keywords

Heat Exchanger, Shell and Tube, Thermal Design, Optimization, Energy Efficiency, Industrial Applications, Heat Transfer, Surface Area Reduction, Flow Rate, LMTD, Design Parameters

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Cite This Article

M. Ashraf and N. Khare, “Design and Optimization of Heat Exchanger Systems for Industrial Applications,” Radius: Journal of Science and Technology 2(1) (2025) 251006. https://doi.org/10.5281/zenodo.15327130

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