Abstract:

Heat exchangers are essential parts of contemporary industrial and energy systems because they control the flow of thermal energy in a variety of applications, from chemical processing to power production. Their effectiveness has a significant impact on operational expenses, energy conservation, and overall system efficiency.  Interest in cutting-edge techniques for evaluating and improving heat exchanger performance has increased recently due to the rising demand for high-efficiency and sustainable systems. With an emphasis on both traditional and cutting-edge methods, this paper summarizes advancements in thermal analysis and optimization.  While experimental studies continue to confirm and improve theoretical models, numerical approaches, particularly computational fluid dynamics (CFD), finite element, and finite volume methods, offer more accuracy and flexibility.  Additionally, optimization techniques are changing, moving from empirical correlations and parametric studies to sophisticated metaheuristic algorithms like particle swarm optimization, genetic algorithms, and hybrid approaches.  Additionally, balanced design solutions are being made possible by thermo-economic frameworks that incorporate life-cycle evaluation and exergy analysis.  Digital tools and platforms, such as CFD software, digital twins, and AI-based design tools, are also examined in the assessment. Nanofluids, additive manufacturing, and integration with renewable energy sources are highlighted in emerging directions.  The necessity for ongoing innovation in simulation-driven and data-assisted design is highlighted by the identification of important problems, which include computing cost, material deterioration, and scalability.