Wei-Mon Yan , Hao-Ming Ma , Jhih-Wei Chen , Chun-Han Li , Saman Rashidi , Seyed Mohammad Vahidhosseini
{"title":"Thermal management and heat transfer enhancement in air conditioning systems with chillers through smart control of chilled water backup systems","authors":"Wei-Mon Yan , Hao-Ming Ma , Jhih-Wei Chen , Chun-Han Li , Saman Rashidi , Seyed Mohammad Vahidhosseini","doi":"10.1016/j.csite.2025.106527","DOIUrl":"10.1016/j.csite.2025.106527","url":null,"abstract":"<div><div>Air conditioning systems are significant contributors to electricity consumption in building operations, making thermal management and energy efficiency critical. This study focuses on enhancing the thermal performance and heat transfer efficiency of the chilled water system by implementing smart control of variable frequency chillers during low-load operations. Monthly cumulative cooling capacities and chilled water circulation data were analyzed, selecting January, February, March, November, and December for nighttime low-load energy-saving experiments. Regression models for each chiller were established, using indices such as R<sup>2</sup>, P-value, YIF, and average error rate of Y-values to validate the performance equations. Results demonstrated a significant positive correlation between load rate and chiller efficiency. During the selected months, operational data revealed efficiency improvements and energy-saving cumulative effects. The findings indicate that employing the chilled water interconnection pipeline system for load transfer increases chiller load rates, enhancing overall system efficiency and reducing the total power consumption of auxiliary equipment. The total energy saved during the operation amounted to 607,738 kWh, leading to a reduction in carbon emissions of 257,681 kg-CO<sub>2</sub>, equivalent to the annual carbon sequestration of Daan Forest Park (approximately 110.5–242.6 metric tons).</div></div>","PeriodicalId":9658,"journal":{"name":"Case Studies in Thermal Engineering","volume":"73 ","pages":"Article 106527"},"PeriodicalIF":6.4,"publicationDate":"2025-06-17","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144322537","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
{"title":"A theoretical insight on interfacial heat transfer in BC3–h-BN heterostructure","authors":"Sina Karimzadeh , Babak Safaei , Tien-Chien Jen","doi":"10.1016/j.csite.2025.106534","DOIUrl":"10.1016/j.csite.2025.106534","url":null,"abstract":"<div><div>Efficient thermal management is critical for the reliability of nanoelectronic devices. This study explores interfacial thermal transport in BC<sub>3</sub>–<em>h</em>-BN van der Waals heterostructures using nonequilibrium molecular dynamics simulations. Two configurations (S1 and S2) were analyzed to evaluate the effects of interfacial bonding, heat flow direction, vacancy defects, and mechanical strain on interfacial thermal conductivity (ITC), thermal resistance (ITR), temperature jump (ΔT), and thermal rectification (TR). The S2 structure showed superior thermal transport with an ITC of 5.93 GW/m<sup>2</sup>. K and ITR of 0.168 K m<sup>2</sup>/GW, compared to 5.29 GW/m<sup>2</sup>. K and 0.189 K m<sup>2</sup>/GW for S1. Heat transfer from BC<sub>3</sub> to <em>h</em>-BN was more efficient, demonstrating rectification behavior. In S1, vacancy defects reduced ITC by 29.83–33.27 %, and 10 % tensile strain caused reduction of up to 17.77 %. Phonon density of states analysis revealed that thermal transport depends on vibrational mode overlap at the interface. Von Mises stress analysis indicated higher mechanical stability in the <em>h</em>-BN layer and better strain resistance in S2. These results underscore the tunability of thermal properties in BC<sub>3</sub>–<em>h</em>-BN heterostructures and offer guidance for designing thermally efficient materials for next-generation nanoelectronic and thermal management systems.</div></div>","PeriodicalId":9658,"journal":{"name":"Case Studies in Thermal Engineering","volume":"73 ","pages":"Article 106534"},"PeriodicalIF":6.4,"publicationDate":"2025-06-17","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144335521","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
{"title":"Optimization of plate-fin heat sink configurations for enhanced thermal performance and manufacturability","authors":"Panit Kamma , Kittipos Loksupapaiboon , Juthanee Phromjan , Machimontorn Promtong , Chakrit Suvanjumrat","doi":"10.1016/j.csite.2025.106529","DOIUrl":"10.1016/j.csite.2025.106529","url":null,"abstract":"<div><div>Enhancing heat sink efficiency presents a significant challenge, requiring the optimization of heat transfer performance while minimizing pressure drop across the inlet and outlet. Although previous designs have improved heat sink performance, their complex geometries have resulted in high manufacturing costs. This study introduces four novel plate-fin heat sink configurations—fillet, chamfer, step, and concave fillet—designed for enhanced manufacturability. A conjugate heat transfer model was employed to analyze forced convection heat transfer over a Reynolds number (Re) range of 500–5000, with laminar and turbulence models validated against experimental data to ensure accuracy near the interface surface. The results indicate that the k-ω turbulence model achieved excellent predictive accuracy, with an average experimental error of less than 5.07 %. Moreover, the fillet, chamfer, step, and concave fillet plate-fin heat sinks exhibited thermal enhancement efficiencies exceeding those of conventional designs at the Re = 5000 by 17.3 %, 15.9 %, 0.8 and 4.6 %, respectively. However, the step plate-fin heat sink did not yield thermal performance improvements despite a lower friction factor than the conventional design. To support future heat sink development, the optimized t/R and t/C ratios were determined to be 2.0 and 1.2 for the fillet and chamfer plate-fin heat sinks, facilitating maximum enhancement of both design and manufacturing processes.</div></div>","PeriodicalId":9658,"journal":{"name":"Case Studies in Thermal Engineering","volume":"73 ","pages":"Article 106529"},"PeriodicalIF":6.4,"publicationDate":"2025-06-17","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144322539","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Mohammed Al-Shalabi , Mohammad Shehab , Mohammad T. Alshammari , Meshari Alazmi , Rami O. Alrawashdeh , Mohammed A. Mahdi
{"title":"Enhanced lotus effect optimization algorithm for efficient problem-solving in high-dimensional complex landscapes","authors":"Mohammed Al-Shalabi , Mohammad Shehab , Mohammad T. Alshammari , Meshari Alazmi , Rami O. Alrawashdeh , Mohammed A. Mahdi","doi":"10.1016/j.csite.2025.106437","DOIUrl":"10.1016/j.csite.2025.106437","url":null,"abstract":"<div><div>The lotus effect optimization algorithm (LEOA) is a metaheuristic technique based on the self-cleaning functionality of the lotus flower and other adaptive features. Although LEOA is effective in optimization exercises, it encounters challenges like early stagnation and an imbalanced trade-off between exploration and exploitation. These shortcomings restrict the performance of the algorithm in some complex high-dimensional problem spaces. This paper proposes an enhanced LEOA (ELEOA), in which LEOA is integrated with particle swarm optimization (PSO) to improve convergence rate, stability, and search effective-ness. To validate the performance of ELEOA, it was benchmarked against 12 recent algorithms assessed on a collection of 20 classical benchmarks along with the IEEE CEC 2019 suite. Experimental results demonstrate that ELEOA outperformed competing algorithms on 18 out of 20 classical functions and ranked among the top three in 18 of the 20 CEC 2019 functions. In terms of convergence speed, ELEOA achieved a 35.7 % improvement over the average of all compared algorithms. Furthermore, the algorithm was applied to three engineering design problems, where it achieved optimal or near-optimal solutions with reduced computational cost. These results confirm ELEOA's robustness, accuracy, and potential for solving complex real-world optimization problems.</div></div>","PeriodicalId":9658,"journal":{"name":"Case Studies in Thermal Engineering","volume":"73 ","pages":"Article 106437"},"PeriodicalIF":6.4,"publicationDate":"2025-06-16","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144313075","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Mazhar Hussain , M. Mansoor , Noreen Sher Akbar , Iqra Amer , Taseer Muhammad
{"title":"Thermal management optimization in electric vehicle batteries using Fe3O4+CoFe2O4/E.G + H2O hybrid micropolar nanofluid","authors":"Mazhar Hussain , M. Mansoor , Noreen Sher Akbar , Iqra Amer , Taseer Muhammad","doi":"10.1016/j.csite.2025.106493","DOIUrl":"10.1016/j.csite.2025.106493","url":null,"abstract":"<div><div>This study investigates at the development of a high-efficiency refrigeration system for new lithium-ion battery packs used in electric cars, with an emphasis on critical thermal management factors including uniformity of temperatures and heat dissipation efficiency The three-dimensional flow of the <em>Fe</em><sub>3</sub><em>O</em><sub>4</sub> <em>CoFe</em><sub>2</sub><em>O</em><sub>4</sub><em>/E.G</em> + <em>H</em><sub>2</sub><em>O</em> hybrid micropolar nanofluid is considered. The flow is modeled mathematically in partial differential equations and then transformed to the equivalent set of nonlinear ordinary differential equations using appropriate similarity transformations. These equations are numerically solved using the Matlab bvp4c module. The graphical analysis explores the importance of micro-polar factors in improving axial heat transfer and the requirement for specific magnetic field orientations to maximize thermal performance across various flow directions. Adjustments to angular velocity and porosity parameters highlight the importance of strategic cooling channel design in facilitating efficient fluid dynamics and reducing flow resistance, hence increasing cooling system efficacy. The findings also determine the issues provided by growing nonlinear radiation, heat source intensity, and temperature difference coefficients, which require strong and novel cooling methods to properly control increased heat generation and temperature sensitivity. These next-generation battery packs can achieve greater thermal control by incorporating modern cooling technologies and improving cooling system designs resulting in optimal operating temperatures and increased overall vehicle dependability and economy.</div></div>","PeriodicalId":9658,"journal":{"name":"Case Studies in Thermal Engineering","volume":"73 ","pages":"Article 106493"},"PeriodicalIF":6.4,"publicationDate":"2025-06-16","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144329808","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Qing Li , Yujing Cheng , Lingyong Ma , Yang Liu , Ting Xue , Xinyao Li , Qinglin Cheng
{"title":"Melting characteristics and heat storage/release mechanisms of millimeter-scale glass spheres encapsulated phase change materials","authors":"Qing Li , Yujing Cheng , Lingyong Ma , Yang Liu , Ting Xue , Xinyao Li , Qinglin Cheng","doi":"10.1016/j.csite.2025.106514","DOIUrl":"10.1016/j.csite.2025.106514","url":null,"abstract":"<div><div>This study bridges critical research gaps in millimeter-scale glass sphere encapsulated phase change materials (GSPCM), where previous work has been limited by: insufficient understanding of heat transfer mechanisms in the 1–10 mm size range that balances structural integrity and thermal response, and absence of validated models accounting for concurrent conduction-convection-phase change interactions. Paraffin-air GSPCM systems (6–10 mm diameter, >75 % PCM loading) were analyzed using coupled experimental and computational fluid dynamics (CFD) approaches, revealing three distinct melting regimes: conduction-dominant (0–20s), transitional (20–40s), and convection-dominant (40–98s). High-speed thermal imaging uncovers a “dual-vortex” flow pattern that enhances heat transfer by 38–42 % compared to pure conduction - a phenomenon previously unreported for this scale. Key advancements include that diameter-dependent scaling laws showing R<sup>3</sup> volumetric storage (10 mm stores 403.79 % more than 6 mm) versus R<sup>2</sup> heat transfer rates (peak 0.6696 J/s at 50 °C). A validated VOF-enthalpy model (error<5 %) capturing multiphysics interactions (conduction-convection-volume change). In addition, it has also been found that increasing the temperature difference can shorten the time and reduce the heat release rate. This offers guidance for millimeter-scale encapsulated PCM applications and heat transfer studies.</div></div>","PeriodicalId":9658,"journal":{"name":"Case Studies in Thermal Engineering","volume":"73 ","pages":"Article 106514"},"PeriodicalIF":6.4,"publicationDate":"2025-06-16","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144307016","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
S.A. Ohid , M.K. Nayak , Rifaqat Ali , Mohamed Kallel , S. Nazari
{"title":"Thermal management of nano-encapsulated PCMs inside a porous wavy U-shaped energy storage system subject to Boussinesq approximation and fusion temperature","authors":"S.A. Ohid , M.K. Nayak , Rifaqat Ali , Mohamed Kallel , S. Nazari","doi":"10.1016/j.csite.2025.106520","DOIUrl":"10.1016/j.csite.2025.106520","url":null,"abstract":"<div><div>Many devices require precise temperature control within a constrained temperature range because they are susceptible to irregular temperature increases or gradients. Indeed, because different building materials have differing coefficients of thermal expansion, a device's sensitive structures may experience internal thermal stress due to temperature variations. Consequently, nano-encapsulated PCMs show promise in terms of their ability to ameliorate working fluid performance while maintaining the devices at a certain cooling temperature. The present article, therefore, numerically investigates the behavior of NC and entropy generation of NEPCM suspension inside a U-shaped thermal energy storage system with a wavy-shaped heater. Modeled governing equations were solved numerically by FEM. The behavior of heat capacity ratios, temperature distributions, fluid structure, entropy generation, and heat transfer efficiency were explored via graphical presentations. It is noticed that augmentation of horizontal displacement of the wavy heater <span><math><mrow><mo>(</mo><mrow><mi>H</mi><mi>D</mi></mrow><mo>)</mo></mrow></math></span>, Rayleigh number <span><math><mrow><mo>(</mo><mrow><mi>R</mi><mi>a</mi></mrow><mo>)</mo></mrow></math></span>, porosity of the medium <span><math><mrow><mo>(</mo><mi>ε</mi><mo>)</mo></mrow></math></span>, and Darcy number <span><math><mrow><mo>(</mo><mrow><mi>D</mi><mi>a</mi></mrow><mo>)</mo></mrow></math></span> upsurges the stream function, isotherms, and heat capacity ratio, velocities, and entropy generation. It is also visualized that <span><math><mrow><mi>N</mi><msub><mi>u</mi><mrow><mi>a</mi><mi>v</mi><mi>e</mi></mrow></msub></mrow></math></span> increases by 85.72 %, 25.51 %, 49.16 %, 0.75 %, 0.49 % respectively due to the enhancement of <span><math><mrow><mi>R</mi><mi>a</mi></mrow></math></span> from <span><math><mrow><msup><mn>10</mn><mn>5</mn></msup><mspace></mspace><mtext>to</mtext><mspace></mspace><msup><mn>10</mn><mn>6</mn></msup></mrow></math></span>, <span><math><mrow><mi>ε</mi></mrow></math></span> from 0.1 to 0.9, <span><math><mrow><mi>D</mi><mi>a</mi></mrow></math></span> from <span><math><mrow><msup><mn>10</mn><mrow><mo>−</mo><mn>4</mn></mrow></msup><mspace></mspace><mtext>to</mtext><mspace></mspace><msup><mn>10</mn><mrow><mo>−</mo><mn>2</mn></mrow></msup></mrow></math></span>, Stefan number from 0.5 to 0.7, fusion temperature from 0.1 to 0.5.</div></div>","PeriodicalId":9658,"journal":{"name":"Case Studies in Thermal Engineering","volume":"73 ","pages":"Article 106520"},"PeriodicalIF":6.4,"publicationDate":"2025-06-16","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144322540","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
{"title":"Numerical investigation of ventilation performance in an impinging jet system with high-level placement","authors":"Chen Wang, Huifan Zheng, Yin Liu, Ke Hu, Xu Yan","doi":"10.1016/j.csite.2025.106479","DOIUrl":"10.1016/j.csite.2025.106479","url":null,"abstract":"<div><div>The indoor ventilation performance of an impinging jet ventilation (IJV) system with high-level placement in non-occupied zone was comprehensively investigated using numerical simulation methods. Combined with response surface methodology (RSM), the differences in thermal comfort and energy efficiency between high-level and low-level placements were quantified for different seasonal conditions. The results indicate that in summer, thermal buoyancy resistance is relatively low, and buoyancy facilitates the accumulation of cool air in the occupied zone, forming a comfortable ventilation environment. Minimal differences were observed between the ventilation environments induced by high-level and low-level air supply placements. Conversely, in winter, the warm airflow from the supply is significantly affected by buoyancy, often rising prematurely unless delivered with high inertial force, in which case high-level placement can achieve performance comparable to low-level placement. The quantitative analysis using RSM revealed that in summer, the thermal comfort and energy efficiency of both high-level and low-level placements were nearly equivalent, with high-level placement slightly outperforming in terms of thermal comfort, while low-level placement demonstrated marginally better energy efficiency. In winter, low-level placement exhibited clear advantages in heating ventilation performance. This study provides theoretical support for the efficient design of IJV systems.</div></div>","PeriodicalId":9658,"journal":{"name":"Case Studies in Thermal Engineering","volume":"73 ","pages":"Article 106479"},"PeriodicalIF":6.4,"publicationDate":"2025-06-15","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144335522","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
{"title":"Influence of CO2 injection timing on enhanced coalbed methane recovery using thermo-hydro-mechanical coupled model","authors":"Hexiang Xu , Cheng Zhai , Jizhao Xu , Yong Sun , Ting Liu , Yangfeng Zheng , Hongyang Xu , Ting Huang","doi":"10.1016/j.csite.2025.106510","DOIUrl":"10.1016/j.csite.2025.106510","url":null,"abstract":"<div><div>Delayed CO<sub>2</sub> injection can prevent premature CO<sub>2</sub> breakthrough to production wells during CO<sub>2</sub> enhanced coalbed methane (CO<sub>2</sub>-ECBM) recovery. Currently, the influence of CO<sub>2</sub> injection timing on CO<sub>2</sub>-ECBM recovery is unclear. In this paper, the thermo-hydro-mechanical (THM) coupled model was established to investigate the CO<sub>2</sub>-ECBM recovery with different injection timings. The porosity evolution characteristics and the optimal injection timing were determined. The results show that high-pressure CO<sub>2</sub> injection elevates reservoir pressure and enhances CH<sub>4</sub> production. As injection time increases, reservoir temperature rises, and permeability declines. Delayed CO<sub>2</sub> injection can avoid inefficient injection stage and maintain a higher injection rate. Injection timing showed linear correlations with CH<sub>4</sub> production, CO<sub>2</sub> storage volume, and breakthrough time, and an S-shaped trend with final CH<sub>4</sub> concentration. CO<sub>2</sub> injection shortens the pore pressure-dominated control stage of porosity and amplifies the influence of gas ad/desorption-induced strain. Temperature changes have a minor effect on porosity, but high initial temperature can reduce gas adsorption, significantly affecting porosity. Finally, the optimal injection time was determined as 1000 d. The results are beneficial for improving the CH<sub>4</sub> recovery and realizing the efficient CO<sub>2</sub> storage.</div></div>","PeriodicalId":9658,"journal":{"name":"Case Studies in Thermal Engineering","volume":"73 ","pages":"Article 106510"},"PeriodicalIF":6.4,"publicationDate":"2025-06-14","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144480386","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
{"title":"Thermal-mechanical coupled stress prediction of printed circuit heat exchanger in the supercritical CO2 Brayton cycle","authors":"Junlin Chen , Wenhai Du , Keyong Cheng , Xunfeng Li , Xiulan Huai , Jiangfeng Guo , Pengfei Lv , Hongsheng Dong","doi":"10.1016/j.csite.2025.106521","DOIUrl":"10.1016/j.csite.2025.106521","url":null,"abstract":"<div><div>Printed circuit heat exchanger (PCHE) is widely recognized as the most promising heat exchanger for supercritical CO<sub>2</sub> (SCO<sub>2</sub>) Brayton cycle. Stress assessment is critical to ensuring the safety and longevity of PCHE. This study addresses a critical gap in the thermal-mechanical stress assessment of PCHE for SCO<sub>2</sub> Brayton cycles by developing novel quantitative models to predict equivalent stresses at semicircular channel tips. Unlike conventional ASME codes, which overlook thermal stress, the pseudo-2D ANSYS Workbench model integrating both thermal and mechanical stresses, was used to offer a comprehensive evaluation. Key structural parameters (channel diameter, plate thickness, ridge thickness) and operational parameters (pressure, temperature difference) were analyzed. The results reveal that mechanical stress is most sensitive to cold-side pressure, while thermal stress correlates linearly with temperature gradients. Dimensional analysis yielded predictive formulas for thermal stress (±13.3 % error) and mechanical stress (±14.3 % error), validated against finite element method results. A backpropagation neural network further improved prediction accuracy (errors <10 %). The proposed models streamline PCHE design verification and dynamic control optimization, ensuring safer and more efficient SCO<sub>2</sub> cycle operation. This research advances sustainable energy systems by providing reliable tools for PCHE stress assessment, with potential applications in solar, nuclear, and waste heat recovery systems.</div></div>","PeriodicalId":9658,"journal":{"name":"Case Studies in Thermal Engineering","volume":"73 ","pages":"Article 106521"},"PeriodicalIF":6.4,"publicationDate":"2025-06-14","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144307015","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}