Corrugated Tube Shell-and-Tube Heat Exchanger Using Epoxy-Based Polymer Composite Coatings for Lightweight and Efficient Thermal Systems

Year : 2026 | Volume : 14 | Special Issue 02 | Page : 603 617
    By

    Tanishq Dabhade,

  • Tanmay Gawari,

  • Prashant Nawale,

  • Bhavesh Shah,

  • Shitalkumar Jain,

  • 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 Environmental Engineering, Indian Institute of Technology, IIT Bombay, Maharashtra, India
  4. Director, , PDB Engineers, MIDC, Bhosari, Pune, Maharashtra, India
  5. Professor, Department of Computer Engineering, MIT Academy of Engineering, Alandi (D), Pune, Maharashtra, India
  6. Associate Professor, Department of Mechanical Engineering, MIT Academy of Engineering, Alandi (D), Pune, Maharashtra, India

Abstract

Corrugated tube geometries are widely recognized for their ability to enhance heat transfer through boundary layer disruption and secondary flow generation. In this study, a combined experimental and computational investigation is carried out to evaluate the thermo-hydraulic performance of a shell-and-tube heat exchanger incorporating corrugated stainless steel tubes integrated with an epoxy-based polymer composite coating and housed within a mild steel shell. Unlike conventional metallic systems, the present work introduces a thin layer of thermally enhanced epoxy composite reinforced with boron nitride fillers on the tube surface to reduce weight, improve corrosion resistance, and tailor thermal conductivity. A three-dimensional Computational Fluid Dynamics (CFD) model based on the finite volume method is developed to simulate conjugate heat transfer, capturing the interaction between fluid flow and composite-coated solid domains. The influence of corrugation geometry, flow rate, and effective thermal conductivity of the epoxy composite on heat transfer rate, Nusselt number, pressure drop, and overall effectiveness is systematically analyzed. Experimental validation is performed under controlled operating conditions to ensure model accuracy. The results demonstrate that corrugated tubes significantly enhance convective heat transfer due to strong flow mixing and periodic boundary layer disruption. The incorporation of epoxy-based polymer composites with optimized filler loading improves thermal performance while offering substantial advantages in terms of weight reduction and material durability. An overall enhancement of 30–55% in heat transfer performance is observed compared to plain metallic tubes, with acceptable pressure drop penalties. The study highlights the novelty of integrating polymer composite coatings with geometric modifications, establishing a coupled material–geometry approach for next-generation compact and energy-efficient heat exchanger design.

Keywords: Epoxy polymer composite, corrugated tubes, shell-and-tube heat exchanger, boron nitride fillers, heat transfer enhancement

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

How to cite this article:
Tanishq Dabhade, Tanmay Gawari, Prashant Nawale, Bhavesh Shah, Shitalkumar Jain, Pramod Kothmire. Corrugated Tube Shell-and-Tube Heat Exchanger Using Epoxy-Based Polymer Composite Coatings for Lightweight and Efficient Thermal Systems. Journal of Polymer & Composites. 2026; 14(02):603-617.
How to cite this URL:
Tanishq Dabhade, Tanmay Gawari, Prashant Nawale, Bhavesh Shah, Shitalkumar Jain, Pramod Kothmire. Corrugated Tube Shell-and-Tube Heat Exchanger Using Epoxy-Based Polymer Composite Coatings for Lightweight and Efficient Thermal Systems. Journal of Polymer & Composites. 2026; 14(02):603-617. Available from: https://journals.stmjournals.com/jopc/article=2026/view=241236


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Special Issue Subscription Original Research
Volume 14
Special Issue 02
Received 06/04/2026
Accepted 25/04/2026
Published 08/05/2026
Publication Time 32 Days
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