Thermal Performance Analysis of Heat Exchangers for Industrial Energy Efficiency

Abstract

Optimizing the thermal performance of heat exchangers is key to enhancing industrial energy efficiency. This paper addresses design, analysis, and improvement strategies of heat exchangers, such as counterflow units, plate-fin systems, and heat-pipe configurations. We examine both experimental and numerical performance assessment methods, including laboratory rigs with controlled temperature and flow measurements, CFD simulations, and analytical tools like LMTD and NTU-effectiveness methods Thermal EngineeringWikipedia. Pinch analysis is leveraged for broader system-level optimization, identifying achievable energy savings and heat recovery potential Wikipedia. Material and geometric enhancements—including nanofluids and open-cell foam structures—demonstrate notable improvements in heat transfer coefficients and overall efficiency SpringerLink+1arXivMDPI. Advanced thermal performance metrics including second-law (exergy) analysis are introduced to evaluate irreversibilities and guide design improvements SpringerLink. A multiscale modeling and experimental validation approach is proposed to assess and boost heat exchanger performance, reducing energy waste through optimized heat recovery. Overall, this study offers a unified methodology for diagnosing thermal inefficiencies and guiding practical design enhancements in industrial heat exchange systems.