Thermal analysis and performance investigations of shell and tube heat exchanger using numerical simulations

The steam condenser is a crucial component in power plants, playing a vital role in influencing the overall performance of steam power plants. This paper delves into a detailed assessment of the thermal aspects and evaluation of steam surface condensers. To conduct this rigorous evaluation, we meticulously crafted a three-dimensional (3D) model of a multi-tube single-pass counter-flow heat exchanger using ANSYS Design-Modeller. Within this model, a multiphase mixture model was harnessed to replicate the condensation process that takes place within the condenser. After the model’s development, a series of computational fluid dynamics (CFD) simulations were expertly executed utilizing ANSYS Fluent Workbench. The simulations encompassed diverse cooling water flow rates and steam inlet velocities. Notably, two sets of CFD simulations were carried out: the initial set featured a velocity inlet in the condenser, while the second set involved CFD simulations with a pressure steam inlet. The findings derived from these simulations unveiled a noteworthy correlation between the condensation rate within the shell and both the rate of circulating water flow and the operational pressure of the condenser. Additionally, it was discerned that the condensation rate could be further influenced by the specific geometry of the condenser. In sum, this study concludes that optimizing the geometrical configuration and baffle arrangements holds promise for increasing the condensation rate and overall performance of steam condensers employed within steam power plants.