Mathematical Modeling
Vol. 9 (2025), Issue 1, pg(s) 30-33

MATHEMATICAL MODELLING OF TECHNOLOGICAL PROCESSES AND SYSTEMS

CFD and Differential Evolution Optimization of an Air-To-Air Heat Recovery System for an Industrial Dryer

  • 1 KANSAN R&D Center, Izmir, Turkiye
  • 2 KANSAN R&D Center, Izmir, Turkiye; Ege University, Department of Mechanical Engineering, Izmir, Turkiye

Abstract

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.

Keywords

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