A MATLAB simulation-based analytical study of energy, exergy, and cost benefits in jet-impinged protrusion-roughened double pass solar air collector

This study analyzes the performance and cost-effectiveness of a protrusion-roughened jet-impinged double-pass solar air collector (PRJDPSAC) within a Reynolds number (Re) range of 2500 to 22,500. Examining jet slot parameters, i.e., the jet height ratio (H_jp/D_hd = 0.11–0.44), stream-wise pitch ratio (X_jp/D_hd = 0.44–1.32), and span-wise pitch ratio (Y_jp/D_hd = 0.44–1.32), the model demonstrates enhanced energy conversion, minimizes losses, improves efficiency, and brings positive economic impact, making it a promising solution for diverse applications including drying processes, livestock facilities, remote accommodations, and HVAC system pre-heating. The examination incorporates advanced MATLAB simulations to assess energy-exergy performance and cost viability. At lower Re values, both energy ( \({\eta }_{I}\) ${\eta }_I$ ) and exergy ( \({\eta }_{II}\) ${\eta }_{\mathit{II}}$ ) efficiencies increase uniformly; however, stabilization and decline occur at higher Re values. The maximum \({\eta }_{II}\) ${\eta }_{\mathit{II}}$ for the PRJDPSAC is 4.38% under a temperature rise parameter of 60 × 10⁻³ Km²/W for obtaining optimum values of X_jp/D_hd = 1.32, H_jp/D_hd = 0.22, and Y_jp/D_hd = 1.32, which is 31% higher than that of the smooth double-pass solar air collector (DPSAC). Economic benefits are significant for PRJDPSAC within m_air (0.01–0.07 kg/s), but above 0.07 kg/s, the DPSAC becomes more cost-effective. Integrating simulation and experimental data, the study highlights MATLAB’s effectiveness for solar energy system analysis and optimization, reinforcing the practicality of the proposed collector design.