A comprehensive design and optimization of an offset strip-fin compact heat exchanger for energy recovery systems

Abstract

• Parametric, sensitivity, and optimization of compact heat exchanger is presented. • A normalized sensitivity analysis is used to identify the critical parameters. • Geometric parameters and fluid velocity appeared as the most influential parameters. • The optimization reduced the operational cost by 78%, and the total cost by 77%. Energy recovery in conventional thermal systems like power plants, refrigeration systems, and air conditioning systems has enhanced their thermodynamic and economic performance. In this regard, compact heat exchangers are the most employed for gas to gas energy recovery because of their better thermal performance. This paper presents an economic optimization of a crossflow plate-fin heat exchanger with offset strip fins. A detailed software-based numerical code for thermal, hydraulic, economic, and exergy analysis is developed for three fin geometries. Genetic Algorithm, parametric, and normalized sensitivity analyses are used to discover the most influential parameters to optimize the total cost. The parametric study showed that with the increase of mass flow rates and plate spacing, outlet stream cost and operating cost increased due to the rise in pressure drops. Finally, the optimization reduced the operational cost by ∼78.5%, stream cost by ∼64.5%, and total cost by ∼76.8%.