Optimization of Shell –And -Tube Intercooler in Multistage Compressor System Using CFD Analysis

Abstract

Multi-staging with intercoolers is an efficient technique for reducing the mandatory energy to
drive gas compressors. Increase of efficiency may end up in large energy savings for larger compressor
systems. Optimization of the intercooler is very desirable because the size of compressor system will
increase.
In this thesis, analytical investigations are done on the shell and tube intercooler without and
with 1400
baffles and optimized for better heat transfer rate. The analysis is performed using forced
convective heat transfer to determine flow characteristics of air flowing under turbulent flow conditions.
3D models of the intercooler without and with baffles are done in Creo 2.0.
Thermal and CFD analysis is done on the intercooler. CFD analysis is done under different
boundary conditions. The materials considered for shell and tube intercooler are Aluminum, Titanium and
Copper for thermal analysis and compared for better material. The input of heat transfer coefficient for
thermal analysis is taken from output of CFD analysis.