Methodology for determining convective heat transfer coefficients on the tubesheet surface of shell-and-tube heat exchangers under single-phase flow

Designing shell-and-tube heat exchangers requires reliable methods to calculate the convective heat transfer coefficient (CHTC) on the tubesheet, due to its impact on thermal stress. To address this, we established numerical models for both the tube and shell sides of the tubesheet. Using computational fluid dynamics (CFD), we systematically investigated the distribution of convective heat transfer on the tubesheet surface and its variations with structural and process parameters. The results showed that when fluid flowed into the tubesheet, the average convective heat transfer coefficient on the tube side of the tubesheet surface was 26% higher than when it flowed out. Additionally, the average convective heat transfer coefficient in the perforated region of the tubesheet was 1.39 to 2.57 times greater than in its periphery. Furthermore, the local CHTC on the shell side of the tubesheet surface gradually decreased along the downstream direction from the inlet of the shell-side fluid. Through simulations conducted across various structural and process parameters, we derived empirical formulas to rapidly calculate the average CHTC on the tubesheet surface. These formulas incorporated a tubesheet porosity factor for the tube side and introduced a new method for calculating the equivalent tubesheet diameter on the shell side. Random testing verified that our proposed formula reliably predicted the numerical simulation results.