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<p>This paper introduces a detailed numerical investigation of the thermal and hydraulic performance of a double-pass solar air heater (DPSAH) with semi-spherical balls and perforated baffles as roughness elements. With ANSYS Fluent 2020 R1, the simulations were performed over a Reynolds number (Re) range of 3000–19000 with different ball radius ratios (<i>r/H</i>) between 0.2 and 0.6 and longitudinal pitch ratios (<i>P/H</i>) between 3 and 6. Results reveal greater heat transfer with a significant increase in the Nusselt number (Nu) from 62.24 to 276.06 while <i>r/H</i> had been increased from 0.2 to 0.6 at <i>P/H</i> = 4. This occurs due to increased disturbance of the boundary layer and turbulence. In the same manner, the friction factor (<i>f</i>) increased from 0.080 to 0.168 due to increased flow resistance. However, increasing <i>P/H</i> at constant <i>r/H</i> = 0.6 led to decreasing Nu (from 276.69 to 65.61) and f (from 0.180 to 0.084). The best value of the thermo-hydraulic performance parameter (THPP) of 2.46 at Re = 3000, <i>r/H</i> = 0.6, and <i>P/H</i> = 4 reflects a perfect balance between pressure drop and heat transfer. Compared to the traditional geometries, the present configuration yields an increase in THPP by a maximum of 47.15%. The outcome decides the applicability of using perforated baffles with semi-spherical balls in improving the thermal efficiency of DPSAH systems. These findings can guide subsequent experimental and design optimization studies, particularly for solar drying and heating systems.</p>

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Performance analysis of a roughened double-pass solar air heater using semi-spherical balls and perforated baffles for enhanced thermal and flow properties

  • 期刊论文

  • 发表日期：

    2026年1月29日

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  • Arpit Srivastava,
  • Nitesh Dutt,
  • Ankush Hedau,
  • Ashwani Kumar

摘要

This paper introduces a detailed numerical investigation of the thermal and hydraulic performance of a double-pass solar air heater (DPSAH) with semi-spherical balls and perforated baffles as roughness elements. With ANSYS Fluent 2020 R1, the simulations were performed over a Reynolds number (Re) range of 3000–19000 with different ball radius ratios (r/H) between 0.2 and 0.6 and longitudinal pitch ratios (P/H) between 3 and 6. Results reveal greater heat transfer with a significant increase in the Nusselt number (Nu) from 62.24 to 276.06 while r/H had been increased from 0.2 to 0.6 at P/H = 4. This occurs due to increased disturbance of the boundary layer and turbulence. In the same manner, the friction factor (f) increased from 0.080 to 0.168 due to increased flow resistance. However, increasing P/H at constant r/H = 0.6 led to decreasing Nu (from 276.69 to 65.61) and f (from 0.180 to 0.084). The best value of the thermo-hydraulic performance parameter (THPP) of 2.46 at Re = 3000, r/H = 0.6, and P/H = 4 reflects a perfect balance between pressure drop and heat transfer. Compared to the traditional geometries, the present configuration yields an increase in THPP by a maximum of 47.15%. The outcome decides the applicability of using perforated baffles with semi-spherical balls in improving the thermal efficiency of DPSAH systems. These findings can guide subsequent experimental and design optimization studies, particularly for solar drying and heating systems.