Numerical simulation and topology optimization of fin-and-tube heat exchangers for enhanced performance

IF 5.4 3区工程技术 Q2 ENERGY & FUELS

Thermal Science and Engineering Progress Pub Date : 2025-09-11 DOI:10.1016/j.tsep.2025.104099

Adel Alshayji, Mohammed Al-Bataineh, Nawaf F. Aljuwayhel

{"title":"Numerical simulation and topology optimization of fin-and-tube heat exchangers for enhanced performance","authors":"Adel Alshayji, Mohammed Al-Bataineh, Nawaf F. Aljuwayhel","doi":"10.1016/j.tsep.2025.104099","DOIUrl":null,"url":null,"abstract":"<div><div>This study presents three major structural modifications involving the addition of flow-disturbing structures (FDS) in three different orientations to the fin and tube configuration of a heat exchanger, focusing on circular and elliptical tube shapes to enhance the overall performance. Eight cases, including two base cases, were evaluated using an efficiency index (JF) combining the Colburn and friction factors to assess the performance. The analysis was conducted across multiple Reynolds numbers using COMSOL Multiphysics and the SST k–ω turbulence model, including visualizations of the streamline patterns. In the circular (A1 and A2) and elliptical (B1, B2, and B3) cases, an increased friction factor led to a reduced efficiency index. Structures A1, A2, B1, and B2 achieved the lowest air temperatures, with a 2.2 K reduction compared to the baseline cases. The modified circular tube case A3 showed the best performance amongst circular cases with a 2.8 % improvement in efficiency index JF, owing to improved flow facilitated by a structure-directing fluid into previously unreachable areas. Case A3 underwent five stages of structural optimization using the Nelder-Mead method, targeting fin spacing (H), obstruction surface length (Obst<sub>L</sub>) which refers to FDS’s, vertical tube spacing (Lt), horizontal tube spacing (Li), and the angle (ɵ) of the FDS’s. The fully optimized case A3 achieved an efficiency index improvement of 6.2 %, demonstrating the effectiveness of systematic structural modifications and numerical optimization for heat exchanger performance, highlighting the effectiveness of integrating CFD simulation with numerical optimization to enhance heat exchanger performance.</div></div>","PeriodicalId":23062,"journal":{"name":"Thermal Science and Engineering Progress","volume":"67 ","pages":"Article 104099"},"PeriodicalIF":5.4000,"publicationDate":"2025-09-11","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":"0","resultStr":null,"platform":"Semanticscholar","paperid":null,"PeriodicalName":"Thermal Science and Engineering Progress","FirstCategoryId":"5","ListUrlMain":"https://www.sciencedirect.com/science/article/pii/S245190492500890X","RegionNum":3,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":null,"EPubDate":"","PubModel":"","JCR":"Q2","JCRName":"ENERGY & FUELS","Score":null,"Total":0}

引用次数: 0

Abstract

This study presents three major structural modifications involving the addition of flow-disturbing structures (FDS) in three different orientations to the fin and tube configuration of a heat exchanger, focusing on circular and elliptical tube shapes to enhance the overall performance. Eight cases, including two base cases, were evaluated using an efficiency index (JF) combining the Colburn and friction factors to assess the performance. The analysis was conducted across multiple Reynolds numbers using COMSOL Multiphysics and the SST k–ω turbulence model, including visualizations of the streamline patterns. In the circular (A1 and A2) and elliptical (B1, B2, and B3) cases, an increased friction factor led to a reduced efficiency index. Structures A1, A2, B1, and B2 achieved the lowest air temperatures, with a 2.2 K reduction compared to the baseline cases. The modified circular tube case A3 showed the best performance amongst circular cases with a 2.8 % improvement in efficiency index JF, owing to improved flow facilitated by a structure-directing fluid into previously unreachable areas. Case A3 underwent five stages of structural optimization using the Nelder-Mead method, targeting fin spacing (H), obstruction surface length (Obst_L) which refers to FDS’s, vertical tube spacing (Lt), horizontal tube spacing (Li), and the angle (ɵ) of the FDS’s. The fully optimized case A3 achieved an efficiency index improvement of 6.2 %, demonstrating the effectiveness of systematic structural modifications and numerical optimization for heat exchanger performance, highlighting the effectiveness of integrating CFD simulation with numerical optimization to enhance heat exchanger performance.

查看原文本刊更多论文

翅片管式换热器的数值模拟与拓扑优化

本研究提出了三种主要的结构修改，包括在三种不同的方向上增加流动干扰结构（FDS），以提高换热器的整体性能，重点关注圆形和椭圆管形状。采用结合Colburn和摩擦因素的效率指数（JF）对8个案例（包括2个基本案例）进行了评估。使用COMSOL Multiphysics和SST k -ω湍流模型对多个雷诺数进行了分析，包括流线模式的可视化。在圆形（A1和A2）和椭圆形（B1， B2和B3）情况下，摩擦系数的增加导致效率指数的降低。A1、A2、B1和B2结构达到了最低的空气温度，与基线情况相比降低了2.2 K。改进后的圆形管壳A3在圆形管壳中表现最好，效率指数JF提高了2.8%，这是因为结构导向流体促进了流动，使其进入了以前无法到达的区域。案例A3采用Nelder-Mead方法进行了五个阶段的结构优化，分别针对翅片间距(H)、阻力面长度（ObstL）（指FDS）、垂直管间距（Lt）、水平管间距（Li）和FDS角度(o)进行优化。充分优化后的A3换热器效率指数提高了6.2%，证明了系统结构改造和数值优化对换热器性能的有效性，凸显了CFD模拟与数值优化相结合提高换热器性能的有效性。

本文章由计算机程序翻译，如有差异，请以英文原文为准。

求助全文

约1分钟内获得全文求助全文

来源期刊

Thermal Science and Engineering Progress Chemical Engineering-Fluid Flow and Transfer Processes

CiteScore

7.20

自引率

10.40%

发文量

327

审稿时长

41 days

期刊介绍： Thermal Science and Engineering Progress (TSEP) publishes original, high-quality research articles that span activities ranging from fundamental scientific research and discussion of the more controversial thermodynamic theories, to developments in thermal engineering that are in many instances examples of the way scientists and engineers are addressing the challenges facing a growing population – smart cities and global warming – maximising thermodynamic efficiencies and minimising all heat losses. It is intended that these will be of current relevance and interest to industry, academia and other practitioners. It is evident that many specialised journals in thermal and, to some extent, in fluid disciplines tend to focus on topics that can be classified as fundamental in nature, or are ‘applied’ and near-market. Thermal Science and Engineering Progress will bridge the gap between these two areas, allowing authors to make an easy choice, should they or a journal editor feel that their papers are ‘out of scope’ when considering other journals. The range of topics covered by Thermal Science and Engineering Progress addresses the rapid rate of development being made in thermal transfer processes as they affect traditional fields, and important growth in the topical research areas of aerospace, thermal biological and medical systems, electronics and nano-technologies, renewable energy systems, food production (including agriculture), and the need to minimise man-made thermal impacts on climate change. Review articles on appropriate topics for TSEP are encouraged, although until TSEP is fully established, these will be limited in number. Before submitting such articles, please contact one of the Editors, or a member of the Editorial Advisory Board with an outline of your proposal and your expertise in the area of your review.