International Scientific Journals
of Scientific Technical Union of Mechanical Engineering "Industry 4.0"

This study details the thermal and fluid dynamic performance analysis and geometric optimization of a compact plate heat exchanger designed for waste heat recovery in industrial drying systems. The objective is to preheat fresh process air (25oC) to a target temperature range of 65–70 oC by recovering heat from high-temperature exhaust air (84 oC inlet, 36,000m3/h flow rate). The methodology integrates fundamental thermodynamic assessment (LMTD and  methods) with Computational Fluid Dynamics (CFD) for detailed flow and temperature mapping. Critically, a Differential Evolution (DE) algorithm was applied to optimize plate geometry, channel size, and profile arrangement, subject to a mass constraint, to maximize heat transfer. Results confirm that the optimized design achieves 18-25% natural gas savings and 27.5% higher efficiency compared to conventional systems. This hybrid approach validates the optimized heat exchanger as a highly sustainable and economically viable solution for industrial thermal management.

This study presents the comprehensive design and architectural modeling of a robotic-based multi-packaging machine developed for high-speed and high-precision packaging processes. The system integrates a Delta robot-based pick-and-place unit, advanced servocontrolled horizontal packaging modules, and a modular conveyor design engineered for multi-product stream transfer. This work investigates the core operational challenges, including product flow management, optimized grouping strategies, dynamic conveyor synchronization, coordination of multi-axis servo movements, and the system’s overall operational efficiency. The results indicate that the developed system operates with high stability, achieves superior precision, and significantly enhances production throughput by providing automatic parameter optimization based on product variety, thereby aligning with modern Industry 4.0 requirements.

There are many different models and types of heat exchangers depending on the area of use. The type of fluids involved in heat transfer and their temperature play a critical role in selecting the appropriate model. Common heat exchangers include plate exchangers, tube-type exchangers, air-cooled exchangers, and graphite exchangers. In this study, a sustainable and original heat exchanger system was designed to increase energy efficiency and reduce natural gas consumption by utilizing the waste heat from natural gas. The design prioritizes ease of maintenance and cleaning. Detailed engineering analyses were conducted, and critical engineering errors identified in previous heat exchanger designs were resolved. The developed designs were validated through test studies and experiments, leading to the final design after an optimization process.
As a result of the study, a high-capacity, energy-efficient, and sustainable heat exchanger integrated with modern technology was developed.