Simulation of a shell-tube heat exchanger in the oil and gas industry
Authors: Kubakh Serhii , Tsapar Vitalii 
Published: October 2023

From the analysis of available literary sources, it follows that the most effective way of introducing heat exchangers into production processes is by using computational fluid dynamics (CFD) modeling. This method also involves fine-tuning the components from which the model is formed. Energy efficiency, safety, and stable functionality of units are key aspects of production activities. CFD modeling provides ample opportunities for studying heat exchange processes in thermal installations, such as tubular heat exchangers. Optimizing the operation of such systems implies careful adjustments, including creating a three-dimensiona l model taking into account real dimensions, and flexible adjustment of various flow regimes and thermal conditions.

Process flow heating and cooling processes are standard practice in various industries. These operations are often performed in heat exchangers where the fluid flows through tubes in laminar conditions. Heat transfer mechanisms in such conditions are complex and not yet fully explored, as they include both forced and natural convection. This creates difficulties in accurately predicting the design of the heat exchanger. The use of simplified geometric models and limited information about oil refining processes in computer simulations significantly affects the analysis and optimization possibilities. This approach can significantly accelerate the development of new types of heat exchangers. Current research emphasizes design changes to improve heat transfer and other performance.

Previous studies note a lack of specific recommendations for design improvement, incomplete investigation of the causes of inaccurate results, and insufficient detail of important parameters. This study presents the model setup steps with emphasis on the important details of the heat exchanger. The grid adjustment process and the properties of the incoming oil are described. The impact of turbulence on crude oil and steam temperature changes is considered. The influence of speed on the heat exchange coefficient was also analyzed in detail, and prospects for further optimization were determined. The application of computer modeling in the oil and gas industry is important. It is a key tool for improving the efficiency, security, and sustainability of operations in the industry.

Computer modeling allows you to predict and optimize processes, create accurate virtual models of objects, analyze their security, and research new technologies. It also facilitates economic analysis, staff training, and innovation. As a result, computer simulation improves decisions, reduces risks, and promotes the development of the entire oil and gas industry. It is one of the effective methods of studying physical systems. Often, computer models are easier and more convenient to study, they allow conducting computational experiments, the real setting of which is difficult or can give an unpredictable result. All these aspects together are aimed at a deeper and more detailed understanding of heat exchange processes, which reveals the potential for improving this process in the future.

The main focus in this context is on the fundamental aspects of developing simulation models when using specialized software. The obtained results of the analysis and adjustment allow a deeper understanding of the model configuration process and the prospects for its further optimization. Increasing the flow rate promotes more efficient heat exchange due to the higher velocity of the medium. A linear dependence of the heat distribution along the length of the pipe and the heat transfer coefficient is obtained in the process of modeling.