Heat Exchanger Case Study

The main challenge lay in accurately simulating and validating the flow distribution within a complex multi-pass heat exchanger. Under low-flow conditions, predicting performance becomes particularly sensitive to small geometric and flow variations, making precise modelling essential. To produce reliable results, the team needed to combine detailed CFD analysis with analytical methods that could cross-check and verify the accuracy of the simulation outputs.

Jesmond Engineering performed a full CFD simulation of the heat exchanger to analyse flow distribution across the header manifold and through each pass. The simulation incorporated detailed geometry and operating parameters, supported by analytical calculations for verification. Mass flow rates were monitored at each pass, and pressure drop across the entire system was assessed to confirm hydraulic performance under the specified conditions.

The simulations revealed that the flow distribution across the exchanger under low-flow conditions was more uniform than initially expected. Combined with the pressure drop analysis, these results allowed Jesmond Engineering to recommend a lower minimum operating flow rate than previously thought possible—improving system efficiency without compromising performance.

By leveraging advanced CFD and analytical validation, Jesmond Engineering provided the client with a data-driven understanding of their heat exchanger’s performance envelope. This insight enabled them to operate the system more efficiently, reducing pumping energy requirements and operational costs. The ability to verify and confidently lower the minimum flow rate also enhanced design flexibility for future systems, ensuring reliable, efficient performance with reduced energy consumption and improved sustainability credentials.