Thermo-Hydraulic Enhancement of Annular Finned Shell-and-Tube Heat Exchangers Using Epoxy-Based Polymer Composites: A Material–Geometry Coupled CFD Investigation

Year : 2026 | Volume : 14 | Special Issue 02 | Page : 669 684
    By

    Omkar Karlekar,

  • Prathmesh Galande,

  • Om Pol,

  • Sunita Barve,

  • Pramod Kothmire,

  1. UG Scholar, Department of Mechanical Engineering, MIT Academy of Engineering, Alandi (D), Pune, Maharashtra, India
  2. UG Scholar, Department of Mechanical Engineering, MIT Academy of Engineering, Alandi (D), Pune, Maharashtra, India
  3. PG Scholar, Department of Mechanical Engineering, MIT Academy of Engineering, Alandi (D), Pune, Maharashtra, India
  4. Professor, Department of Computer Engineering, MIT Academy of Engineering, Alandi (D), Pune, Maharashtra, India
  5. Associate Professor, Department of Mechanical Engineering, MIT Academy of Engineering, Alandi (D), Pune, Maharashtra, India

Abstract

Shell-and-tube heat exchangers remain a backbone of industrial thermal systems, yet their performance is often limited by relatively low shell-side heat transfer and the weight and cost associated with conventional metallic components. In this context, the integration of polymer composite materials offers a promising pathway toward lightweight, corrosion-resistant, and performance-tunable heat exchanger designs. The present study investigates the thermo-hydraulic performance of a straight-tube shell-and-tube heat exchanger equipped with annular fins, with particular emphasis on the role of epoxy-based polymer composites reinforced with thermally conductive fillers such as graphite and boron nitride. A three-dimensional computational fluid dynamics (CFD) model is developed to analyze the coupled influence of material thermal conductivity and fin geometry on heat transfer and flow behavior. The tube domain is modeled using both conventional stainless steel and polymer composite materials with varying effective thermal conductivity, while the shell is retained as mild steel for structural integrity. A parametric study is performed by varying fin pitch and fin height to evaluate their effect on shell-side heat transfer, temperature distribution, and pressure drop. The governing continuity, momentum, and energy equations are solved under steady-state conditions, and model accuracy is ensured through mesh independence analysis. The results indicate that annular fins significantly enhance heat transfer by increasing effective surface area and promoting flow mixing. The use of thermally enhanced polymer composites demonstrates competitive performance, particularly when combined with optimized fin geometry. While lower conductivity composites introduce additional thermal resistance, this effect is effectively compensated by geometric enhancement. An improvement in heat transfer performance is observed compared to plain tube configurations, with acceptable pressure drop penalties. The study highlights that optimal performance is achieved through a balanced integration of material properties and geometric design, demonstrating potential of polymer composites as viable alternatives to conventional metallic heat exchanger components.

Keywords: Epoxy-based polymer composites; shell-and-tube heat exchanger; annular fins; thermal conductivity; CFD; heat transfer enhancement; thermo-hydraulic performance

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

How to cite this article:
Omkar Karlekar, Prathmesh Galande, Om Pol, Sunita Barve, Pramod Kothmire. Thermo-Hydraulic Enhancement of Annular Finned Shell-and-Tube Heat Exchangers Using Epoxy-Based Polymer Composites: A Material–Geometry Coupled CFD Investigation. Journal of Polymer & Composites. 2026; 14(02):669-684.
How to cite this URL:
Omkar Karlekar, Prathmesh Galande, Om Pol, Sunita Barve, Pramod Kothmire. Thermo-Hydraulic Enhancement of Annular Finned Shell-and-Tube Heat Exchangers Using Epoxy-Based Polymer Composites: A Material–Geometry Coupled CFD Investigation. Journal of Polymer & Composites. 2026; 14(02):669-684. Available from: https://journals.stmjournals.com/jopc/article=2026/view=242881


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Special Issue Subscription Original Research
Volume 14
Special Issue 02
Received 13/04/2026
Accepted 04/05/2026
Published 14/05/2026
Publication Time 31 Days
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