The need to address energy challenges and environmental pollution has led researchers to focus on utilizing solar energy. In this study, a new solar air heater collector system was developed that incorporates arc-shaped wire roughness and external airflow recycling. The system performance was evaluated under various conditions using energy conservation equations and a semi-analytical method for modeling. The results were validated, confirming the method’s accuracy. The findings revealed that the hybrid system significantly improved energy and exergy efficiencies at lower mass flow rates. Increasing the airflow recycle ratio up to 3 in conditions of constant roughness and low mass flow rates enhanced collector performance. However, at high flow rates and recycle ratios, exergy efficiency decreased due to increased pressure drop, despite a rise in energy efficiency, making it less effective than a simple collector system. The results show that the temperature increase is not so much from a mass flow rate of more than 0.05 kg/s. The existence of considered artificial roughness has caused an increase in temperature, especially in mass flow rates of less than 0.035 kg/s.
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