Innovative Shell-and-Tube Heat Exchanger Design for Automotive Radiator Replacement: A Novel Approach to Replacing Car Radiators

Document Type : Research Paper

Authors

Department of Mechanical Engineering, University of Tabriz, Tabriz, Iran

10.22104/hfe.2025.7378.1341

Abstract

A radiator is a crucial component of the engine’s cooling system, responsible for dissipating heat from a mixture of antifreeze and water. It releases excess heat while allowing cool air to pass through before circulating the cooled fluid back to the engine. One of the challenges of using a radiator is its installation location in different vehicles. In passenger cars and trucks, the radiator is typically positioned at the front of the vehicle. As a result, in front-end collisions, this compact and delicate heat exchanger is highly susceptible to severe damage. Additionally, the leakage of coolant from the damaged radiator can further compromise the vehicle’s functionality. The purpose of this research is to introduce a new system consisting of a shell-tube heat exchanger that replaces the traditional radiator while performing the same cooling function. This system is designed with consideration of existing radiator-related issues, aiming to improve both volume efficiency and safety. In this study, a low-error simulation was conducted for the Om457-946 diesel engine produced by IDEM Tabriz Company, which has a test report and an accurate performance curve. The results indicate that the heat load at no load and 900 rpm is 65.3125, while at full engine load and 2000 rpm, it reaches 120.9513. Additionally, the designed shell-and-tube heat exchanger model has a 46% smaller volume compared to the current radiator.The shell-and-tube heat exchanger is generally cylindrical in shape, but in this study, the proposed exchanger is designed as a rectangular cube, taking into account computational coefficients, pressure drop, and shape considerations. This design change is one of the innovative aspects of the research. However, the methods and equations used remain consistent with conventional shell-and-tube exchangers. Another novelty of the research is that it increases the radiator's resistance while simultaneously reducing its volume.

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References

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Hydrogen, Fuel Cell & Energy Storage
Volume 12, Issue 4
December 2025
Pages 275-284

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