Aerodynamic and Thermal Optimization of Plate Heat Exchanger Fin Arrangements

Abstract

Plate-fin heat exchanger systems today are exceedingly prevalent but greatly unoptimized because of the use of off-the-shelf heat exchangers, which considerably affect system efficiency. This study aims to provide a methodology for a plate-fin heat exchanger’s aerodynamic and thermal optimization to create a bespoke cooling solution based on given constraints and operating conditions. The authors studied a radiator to cool the EMRAX 208 electric motor to develop the requisite analytical and numerical models. A literature review was undertaken to compare and shortlist the best configurations, optimized through a MATLAB algorithm, and analysed and iterated in Ansys Fluent on a case-by-case basis. The results of the study point towards the superiority of serpentine fins over the other kinds, with approximately 40% higher heat transfer coefficients (at 80kmph) compared to the triangular finned models, which results in an indirect reduction in the frontal area and, subsequently, lower drag and pressure losses. The study concluded with the serpentine finned cylindrical tube heat exchanger as the best cooling solution. The exact dimensions and layout of the heat exchanger, along with the optimal fin distribution, can be obtained with the combination of the created algorithm and CFD analysis.