ABSTRACT An innovative design of solar air heater (SAH) with spiral shape is numerically analyzed in this paper. The spiral-shaped SAH hydro-thermal performance is studied for different air mass flow rates using CFD COMSOL Multiphysics software. The outlet air temperature difference, thermal efficiency, flow structure, thermal field and pressure drop are the main parameters which are considered to estimate the fluid flow and heat transfer behaviors of the SAH. The simulation is realized for 1000 W/m2 of solar heat flux and 25°C of ambient temperature as typical climatic conditions in a middle day. The results show that the maximum outlet temperature difference of the SAH reached 93.08°C with 0.0083 kg/s of air mass flow rate. For the range of 0.0083–0.0332 kg/s, the thermal efficiency is varied from 91.41% to 99.01%. The ambitious percentage of the thermal efficiency of 99.01% was observed for 0.012 kg/s. The proposed design provides high thermal efficiency of SAH compared to other configurations of SAH.