Work

Topology optimization for dual-flow heat exchangers of moderate conductive material within a narrow design domain: Numerical and experimental investigations

Year: 2025

Type: article

Abstract: Heat exchangers (HXs) play a critical role in various energy systems, which can largely influence their overall efficiency. Most recently, the interest in the topology optimization (TO) of heat transfer, which can derive innovative thermal designs, is growing rapidly. Therefore, the present work investigates the utility of the density-based TO for dual-flow HX unit of moderate conductive material (Stainless Steel (SS)) and narrow design domain, along with CFD (computational fluid dynamics) and experimental verifications. The objective of the TO is to maximize the heat exchange rate, while a pressure drop constraint is imposed on the HX’s flow channels to avoid the blocking issues. An in-depth investigation is conducted to study the effect of various TO’s input parameters on the derived topology. The obtained results reveal that the TO-derived design is mainly featured by the solid allocation in proximity to the insulation walls but not at the interface wall that separates hot and cold fluids (where heat is exchanged). Furthermore, high fidelity CFD simulations along with experimental approaches (including Infrared thermography) are employed to validate the TO’s design methodology and the numerical model. The experimental and numerical results present good agreement between each other, demonstrating the thermo-hydraulic performance superiority of the TO-acquired design compared to the benchmark case with an intensification in the exchanged heat up to 15% under the same pumping power. Lastly, a physical interpretation is delivered to analyze the underlying physics behind the TO-acquired topologies.

Source: Applied Thermal Engineering

DOI: 10.1016/j.applthermaleng.2025.125958

Authors: Ahmad Fawaz, Yuchao Hua, Steven Le Corre, Yilin Fan, Lingai Luo, Gwenaël Biotteau

Institutions: Centre National de la Recherche Scientifique, Laboratoire de Thermique et Energie de Nantes, Nantes Université

Language: English

Topic: Topology Optimization in Engineering

Subfield: Civil and Structural Engineering

Field: Engineering

Domain: Physical Sciences

SDG: Affordable and clean energy

Open Access status: hybrid

Estimated APC paid: $3,660