Design and Experimental Analysis of a Shell-and-Tube Heat Exchanger Using Enhanced Fins

Shell-and-tube heat exchangers are among the most widely used thermal equipment in power plants, chemical industries, and HVAC applications due to their robust construction and high heat transfer capacity. Improving their performance while maintaining structural stability is a key engineering challenge, especially in applications requiring compact design and enhanced efficiency. This study focuses on the design and experimental analysis of a shell-and tube heat exchanger equipped with enhanced fins for improved heat transfer. Various fin geometries—rectangular, helical, and perforated fins—were incorporated into the tube bundle to analyze their effect on thermal performance. Experimental testing was conducted using hot water as the tube-side fluid and cold water on the shell side. Parameters such as overall heat transfer coefficient, effectiveness, log mean temperature difference (LMTD), and pressure drop were evaluated for each fin configuration. Results indicated that perforated fins significantly improved turbulence and enhanced heat transfer by up to 22%, while helical fins provided a good balance between heat transfer enhancement and moderate pressure drop. The study concludes that fin geometry plays a crucial role in optimizing heat exchanger performance, and enhanced fins offer a promising pathway for designing more compact and efficient thermal systems.