Investigation to Enhance Performance of Finned U-Tube Shell-and-Tube Heat Exchangers Using Epoxy Based Polymer Composite Material

Year : 2026 | Volume : 14 | Special Issue 02 | Page : 618 633
    By

    Ritesh Patil,

  • Srushti Kamble,

  • Prathmesh Kokare,

  • Mahesh Goudar,

  • Pramod Kothmire,

  1. UG Scholar, Department of Mechanical Engineering, MIT Academy of Engineering, Alandi, Pune, Maharashtra, India
  2. UG Scholar, Department of Mechanical Engineering, MIT Academy of Engineering, Alandi, Pune, Maharashtra, India
  3. UG Scholar, Department of Mechanical Engineering, MIT Academy of Engineering, Alandi, Pune, Maharashtra, India
  4. Professor, Department of Electronics and Telecommunication Engineering, MIT Academy of Engineering, Alandi, Pune, Maharashtra, India
  5. Associate Professor, Department of Mechanical Engineering, MIT Academy of Engineering, Alandi, Pune, Maharashtra, India

Abstract

Shell-and-tube heat exchangers remain indispensable in thermal engineering systems; however, conventional metallic configurations often face challenges related to corrosion, weight, and limited thermal optimization. In this study, a novel approach is proposed by integrating epoxy-based polymer composite materials with finned U-tube geometries to enhance thermo-hydraulic performance while addressing material limitations of traditional systems. The work focuses on the development and evaluation of a hybrid heat exchanger comprising a mild steel shell and stainless steel tubes coated and modified with thermally enhanced epoxy composites embedded with conductive fillers. A combined experimental and three-dimensional Computational Fluid Dynamics (CFD) investigation is carried out to analyze the coupled effects of geometry and material innovation. The CFD model is developed using a conjugate heat transfer framework to simultaneously resolve fluid flow and heat conduction through composite-modified tube walls. Special attention is given to the U-bend region, where complex flow structures such as secondary vortices and recirculation zones significantly influence performance. The k–ω SST turbulence model is employed to accurately capture near-wall effects and flow separation. The results reveal that the incorporation of polymer composite coatings, along with finned tube configurations, leads to enhanced thermal interaction due to increased effective surface area and improved boundary layer disruption. Additionally, the tailored thermal conductivity of epoxy composites provides a controlled heat transfer pathway while offering superior corrosion resistance and reduced system weight. Although a moderate increase in pressure drop is observed, the overall performance evaluation criterion indicates a net gain in thermo-hydraulic efficiency. The novelty of this study lies in the synergistic integration of polymer composite materials with advanced tube geometries, offering a sustainable and high-performance alternative to purely metallic heat exchangers. The findings provide valuable insights for the design of next-generation compact and energy-efficient heat exchangers aligned with the evolving scope of polymer composite engineering.

Keywords: Epoxy-based polymer composite, U-tube heat exchanger, finned tubes, conjugate heat transfer, thermo-hydraulic performance, CFD analysis, heat transfer enhancement

[This article belongs to Special Issue under section in Journal of Polymer & Composites (jopc)]

How to cite this article:
Ritesh Patil, Srushti Kamble, Prathmesh Kokare, Mahesh Goudar, Pramod Kothmire. Investigation to Enhance Performance of Finned U-Tube Shell-and-Tube Heat Exchangers Using Epoxy Based Polymer Composite Material. Journal of Polymer & Composites. 2026; 14(02):618-633.
How to cite this URL:
Ritesh Patil, Srushti Kamble, Prathmesh Kokare, Mahesh Goudar, Pramod Kothmire. Investigation to Enhance Performance of Finned U-Tube Shell-and-Tube Heat Exchangers Using Epoxy Based Polymer Composite Material. Journal of Polymer & Composites. 2026; 14(02):618-633. Available from: https://journals.stmjournals.com/jopc/article=2026/view=240802


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Special Issue Subscription Original Research
Volume 14
Special Issue 02
Received 10/04/2026
Accepted 21/04/2026
Published 02/05/2026
Publication Time 22 Days
45

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