Installation of corrugations on the absorber plate of a solar air heater (SAH) improves its performance. Pentagonal ribs were used as artificial corrugations on the SAH absorber, which is used in an indirect solar dryer. The impact of Reynolds number, Re (4000–22000), corrugation pitch, P (25–200 mm), corrugation height, e (4–20 mm), and corrugation angle, α on the performance of SAH was analyzed by estimating the Nusselt number (Nu), friction factor (f), Nu ratio, f ratio, and thermo-fluidic enhancement index (Etf). Seventeen models were generated in ANSYS DesignModeler. 133 simulations were performed to obtain the optimum pitch (set-1 and 3 simulations) and the optimum height (set-2 simulations) values. Environmental analysis of the SAH was performed by computing the energy payback period (Epb), and CO2 mitigation for a lifetime of 20 years. The Nu increased and the f fell with a rise in Re value. Compared to smooth SAH, the pentagonal ribbed SAH produced a 60–149 % increase in Nu. The highest Etf of 1.839 was obtained at P = 25 mm, e = 7 mm. The proposed optimal dimensions of the pentagonal rib are; e = 7 mm (e/D = 0.05), P = 25 mm (P/e = 3.57), and corrugation angle, α = 18.64°. The Epb and CO2 mitigation are 0.174 years and 57.34 tons, respectively. A comparison of the results with the literature data showed that the present results are acceptable.
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