Design Optimization of Thermal Systems Using the Nusselt Number Correlation Approach

Abstract

Thermal System Design Optimization is an important factor in the improvement of energy efficiency and functional reliability in engineering applications that involve typical thermal systems such as heat exchangers, HVAC systems, and electronic cooling devices. This study outlines a systematic approach to enhancing performance in thermal systems based largely on the Nusselt number, which is a commonly employed design criterion. To gauge thermal performance under several conditions of flow, the Nusselt number is a suitable measure of convective heat transfer. Therefore, the approach described in this study, in terms of geometry, fluid and thermal parameters, will include empirical and semi-empirical correlations of both laminar flow and turbulent flow. The Reynolds number, Prandtl number, surface properties, and several other factors were modified to optimize the heat transfer rates considering: a sensitivity analysis, parametric optimization to reducing pressure drop and energy consumption. The validation of the proposed Framework is based on configurations of microchannels and case studies of portable heat exchangers. The results demonstrate that using Nusselt-based correlations to optimize thermal systems provides an improved, more efficient, and scalable way to enhance thermal design for both conventional and advanced heat transfer systems.