Three-dimensional analysis of thermohydraulic performance in corrugated channels with embedded baffles: Optimization of heat transfer and energy efficiency

Abstract

This study conducts a three-dimensional thermohydraulic analysis of wavy channels equipped with embedded baffles on the upper wall, aiming to optimize heat transfer while minimizing pressure losses. The efficiency of heat exchangers is crucial in many industrial applications, and research efforts have focused on improving their performance through geometric modifications. In this context, baffles play a significant role in increasing turbulence and enhancing heat transfer. Three channel configurations were examined: smooth walls, wavy walls, and wavy walls with rectangular baffles. Numerical simulations validated the model's reliability, with discrepancies below 6.49 % for configurations without baffles and 1.82 % for those with baffles. The results indicate that a baffle height of 5 mm achieves optimal thermal performance, yielding a thermal performance factor of 6.70394 at a Reynolds number of 6000. The introduction of perforated baffles allowed for the exploration of alternative geometries, although increasing the number of perforations reduced the Nusselt number due to decreased recirculation and fluid mixing. For the studied Reynolds number range (1000–6000), the thermal performance factor varies between 6.6022 and 6.7908, depending on the configuration. Models (2) and (4) stand out for their ability to offer an excellent trade-off between thermal performance and energy cost, outperforming the performance of smooth channels. These findings highlight the potential of wavy channels with optimized baffles to enhance the efficiency of thermal systems. Future studies could explore more complex variants of perforated baffles or integrate high-thermal-conductivity materials to further improve performance.