Multi-objective optimization of a semi-cylindrical coil heat exchanger: Integrating numerical simulation and response surface methodology for geometric parameter analysis

This study numerically investigates the thermal and hydrodynamic performance of a novel semi-cylindrical coil heat exchanger, addressing a significant gap in existing research. By focusing on two critical geometric parameters, coil pitch and small-to-large diameter ratio, the research aims to optimize the coil's design for enhanced efficiency. The analysis of three different pitches reveals that the 12 mm pitch geometry consistently provides superior thermal performance, achieving a 56% increase in the Nusselt number compared to the 6 mm pitch. Building on this finding, the study further explores four distinct diameter ratios, demonstrating that a larger diameter ratio significantly improves heat transfer. The coil with a 0.74 diameter ratio shows a remarkable 79.7% increase in the Nusselt number at Re = 500 when compared to the 0.41 ratio. While these enhancements come with an increase in pressure drop, the results prove that the thermal benefits outweigh the hydrodynamic costs. The findings of this research provide valuable design guidelines for engineers and researchers in various industrial applications, including heat recovery, refrigeration, and compact thermal systems. o generalizes these findings, Response Surface Methodology (RSM) was employed to develop highly accurate numerical models for Nu , Pressure Drop ( Δ P ), and Thermal Performance ( η ). A subsequent Multi-Objective Optimization confirmed that the optimal design point lies at the maximum tested parameters ( Re = 2000 and D_r = 0.74), yielding a predicted maximum Nu of 26.99 and a Thermal Performance ( η ) of 2.28. The optimization achieved a near-perfect Combined Desirability of 0.999888, validating the reliability of the suggested optimal configuration. The findings of this research provide valuable design guidelines for engineers and researchers in various industrial applications, including heat recovery, refrigeration, and compact thermal systems.

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