Plate heat exchangers are extensively utilized in thermal management. The heat transfer efficiency is significantly constrained by structural parameters and the non-uniformity of flow distribution across the plates. To address this, this study proposes the integration of diversion grooves onto the heat transfer plates to optimize the flow field. Numerical simulations conducted using ANSYS FLUENT demonstrate that the introduction of diversion grooves effectively reduces the fluid distribution uneven coefficient by 6.9%. To identify the optimal configuration, a series of plate models were developed and analyzed, investigating the impact of varying diversion groove lengths (ranging from 0 to 3/4 of the heat transfer zone width), numbers (0, 3, 4, 5, and 6), and corrugated angles (0°, 15°, 30°, 45°, 60°, and 75°). The results indicate that the optimal performance is achieved when the diversion groove length accounts for 2/3 of the main heat transfer zone with a quantity of four grooves. Compared to the baseline structure without diversion grooves, this configuration yields a 26.2% increase in the comprehensive performance coefficient and a 4.6% reduction in the fluid distribution uneven coefficient. Furthermore, under identical diversion groove configurations, the plate with a 60° corrugated angle exhibits superior performance, surpassing other angles by at least 1.4% in the comprehensive performance coefficient, while maintaining the fluid distribution uneven coefficient within 0.5% of the minimum observed value. These findings provide a theoretical basis for the structural optimization of high-efficiency plate heat exchangers.
Cyclone separators are highly efficient gas-solid separation that operate on the centrifugal force and play an indispensable role in industries such as chemical engineering, environmental protection, and power generation. They exhibit excellent reliability, particularly under demanding conditions such as high temperatures and elevated particle concentrations. However, a persistent trade-off between separation efficiency and pressure drop has limited further performance improvements. To address this, optimization of cyclone separators has become a major research focus. This article systematically reviews recent advances, first by examining the mechanisms through which key structural parameters, such as inlet geometry, exhaust pipe diameter, and cone angle, influence performance across different industrial applications. Furthermore, the review introduces an integrated optimization framework based on computational fluid dynamics (CFD) simulations, surrogate modelling, and intelligent optimization algorithms to enhance design performance. It critically compares the applicability and limitations of various high-dimensional optimization methods and their integration strategies. The article underscores a paradigm shift from optimizing instantaneous performance toward establishing a lifecycle optimization (LCO) framework that incorporates long-term metrics such as wear and maintenance costs. Evidence shows that coupling CFD with intelligent algorithms enables efficient exploration of multi-objective parameter spaces. Finally, the article discusses current limitations in optimization research and outlines future directions, including multi-physics coupling involving flow, heat, and particle transport, lifecycle optimization, and intelligent decision support systems. In summary, this review establishes a theoretical foundation and provides technical guidance for the energy-efficient, high-performance design and industrial implementation of cyclone separators.
Rotary gas-gas heat exchangers (GGHs) are pivotal for waste heat recovery in low- and medium-temperature denitrification systems of cement kilns. This study examines the performance of GGHs within such systems by coupling computational fluid dynamics (CFD) with the response surface method (RSM), introducing overall system performance (OSP) as the principal optimization criterion. The investigation systematically elucidates the effects of treated flue gas inlet temperature, inlet velocity, and rotor speed on GGH efficiency. Findings reveal that OSP increases with rotor speed but reaches a plateau beyond 1 rpm; it decreases with higher inlet velocity and increases with higher inlet temperature. Response surface analysis identifies treated flue gas inlet temperature as the most influential parameter, highlighting a synergistic effect between rotor speed and inlet temperature, alongside an antagonistic interaction between inlet temperature and inlet velocity. To ensure safe system operation, engineering constraints were incorporated into the optimization framework using a Box-Behnken design. The optimal operational parameters were determined as a treated flue gas inlet temperature of 250°C, inlet velocity of 8 m/s, and rotor speed of 1 rpm, yielding a maximum OSP of 107.74. The integrated CFD-RSM methodology and constraint-aware optimization strategy presented in this study offer a practical reference for enhancing the operational efficiency of industrial waste heat recovery systems, particularly in cement kiln SCR applications.
