Numerical Modeling and Optimization of the Geometry of Helically Finned Tubes in Shell-and-Tube Heat Exchangers for Enhanced Heat Transfer and Reduced Pressure Drop

Document Type : Original Article

Author
Mojtaba Babaelahi
1. Associate professor, Department of Mechanical Engineering, University of Qom, Qom, Iran
10.22034/stme.2026.552823.1181
Abstract
Shell-and-tube heat exchangers are widely used in energy, chemical, and HVAC industries due to their mechanical robustness, high thermal efficiency, and ability to withstand elevated pressures and temperatures. This study aims to enhance heat transfer performance while minimizing pressure drop by numerically modeling and optimizing the geometry of helical grooves inside the tubes of such heat exchangers. Thermo-hydraulic analysis was carried out using CFD simulations in COMSOL Multiphysics. Model validation against well-established empirical correlations confirmed the accuracy of the baseline model, with a deviation of less than 6%. The results show that increasing the depth and width of the helical grooves can enhance the heat transfer coefficient by up to 23%, although at the expense of a 20% rise in pressure drop. Finally, the developed model was optimized using a genetic algorithm. The optimization results indicate that the optimal geometry—groove depth of 2 mm, width of 1.5 mm, helix angle of 40°, and 20 grooves—improves the overall thermal performance by 25% compared to smooth tubes.
Keywords
Helical Grooves
Heat Transfer Enhancement
Shell-and-Tube Heat Exchangers
Numerical Simulation
Thermal Performance
Subjects
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  • Receive Date 12 October 2025
  • Revise Date 18 November 2025
  • Accept Date 05 January 2026
  • First Publish Date 05 January 2026
  • Publish Date 23 July 2026