Abstract
Thermodynamic optimization of a heat exchanger design can be described as identifying the best trade-off between surface area, heat transfer efficiency and pressure drop. Most current heat exchanger types have a fixed characteristic geometry along the flow direction, which is logical considering the characteristics of common manufacturing methods. However, constant geometry cross-sections are intuitively sub-optimal when fluid properties change significantly between inlet and outlet. In this work we describe a framework for heat exchanger design optimization and demonstrate it on a novel variable geometry plate-and-fin-type heat exchanger concept for industrial heat recovery. Optimization variables include external casing width and height at several variable positions along the flow axis, and spline interpolation is used to generate continuous and smooth transitions between defined points. The case study results indicate significant potential for specific performance improvement, depending on conditions and constraints.
