Pressure drop optimisation in compact heat exchanger manifolds

Topology optimisation of a shell-side inlet manifold in a TEMA E shell. How we reduced flow maldistribution from 31% to 4% across 222 tubes without touching the bundle configuration.

• Mesh sensitivity study and solver convergence criteria
• Turbulence model selection and near-wall treatment approach
• Validation against physical measurement and LDV data
• Recommendations for industrial design and process applications