CFD simulation of a shell and multiple tubes condensing heat exchanger in a modified microwave plant applied for reprocessing End of Life Tires (ELTs)

Abstract

AbstractThe condensation heat exchanger has a critical role in the microwave reduction process to separate and capture valuable by‐products after the microwave reactor. This study aims to perform a computational fluid dynamics (CFD) simulation of a condenser to assess the heat transfer performance of the heat exchanger comprehensively. The type of heat exchanger used for this study is based upon an existing industrial‐scale condenser taken from a conventional thermal pyrolysis end of tires (ELT) reprocessing plant and repurposed for integration into a 1500 kg/h ELT microwave reduction process. The condenser is a shell‐and‐multiple‐tube heat exchanger in which the syngas passes through the tubes while cold water from a cooling tower is placed inside the shell. After the simulation, the effects of inlet temperatures and mass flow rates of the gas and water are investigated. The results show that the heat transfer rate is 58 kW for the inlet air velocity of 0.25 m/s and increases due to the convective heat transfer by 32% and 55% when the air velocity rises to 0.5 and 1 m/s, respectively, for the inlet gas and water temperatures of 80 and 15°C, respectively. Additionally, because the outlet air temperature and the inlet water temperature are strongly correlated with convective heat transfer, the outlet air temperature is equivalent to 17.2, 22.3, and 29.5°C when the inlet water temperature is 15, 20, and 25°C, respectively.