Twisted-tube rod-baffle exchangers under multi-objective thermal-hydraulic design and operating constraints

Authors

  • Ji-Min Seok School of Mechanical Engineering, Pusan National University, Busan, Republic of Korea

Keywords:

Twisted-tube, Rod-baffle, Multi-objective optimization, Thermal-hydraulic, Computational fluid dynamics

Abstract

The transition toward highly efficient thermal management systems in modern industrial processes necessitates the development of advanced heat exchanger geometries. Among these, the twisted-tube rod-baffle heat exchanger emerges as a highly promising configuration, combining the secondary flow generation capabilities of twisted tubes with the robust, vibration-resistant, and low-pressure-drop characteristics of rod baffles. This study presents a comprehensive investigation into the multi-objective thermal-hydraulic design of such exchangers under stringent operating constraints. A rigorous computational fluid dynamics methodology is established to evaluate the complex three-dimensional flow and heat transfer phenomena within the shell side of the exchanger. The mathematical formulation couples the continuity, momentum, and energy equations with an advanced turbulence model to capture the intricate swirl flows and boundary layer interactions. Subsequently, a multi-objective optimization framework based on the Non-dominated Sorting Genetic Algorithm II is implemented to simultaneously maximize the heat transfer rate and minimize the frictional pressure drop. The decision space encompasses critical geometrical parameters, including the tube twist ratio, rod baffle spacing, and shell diameter, while operating constraints such as maximum allowable pumping power and flow-induced vibration limits are strictly enforced. The optimization yields a Pareto frontier that provides a set of optimal design trade-offs for industrial application. Detailed analysis of the optimal configurations reveals that the synergistic interaction between the twisted tube surfaces and the rod baffles significantly mitigates the formation of dead recirculation zones, thereby enhancing the overall thermal-hydraulic performance.

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References

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Published

2026-09-26

Issue

Vol. 4 No. 2 (2026): International Journal of Innovative Research

Section

Articles

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Copyright (c) 2026 Ji-Min Seok

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