Wyno Journal of Engineering & Technology Research

Vol. 1(2), PP. 21-29 April, 2013.

Available Online at http://www.wynoacademicjournals.org/egineering.html
ISSN 2315 - 9286 2013 Wynoacademic Journals.

Entropy minimization in Plate-fin heat exchanger using Cuckoo
Algorithm
Masoud Asadi
Department of Mechanical Engineering,
Azad Islamic University Science and Research branch,
Tehran, Iran,
Email: masoud2471@gmail.com ,
Tel:+98939-329-3465
Accepted Date: 15
Th
April ,2013
Abstract
One of the key stages in designing a heat exchanger is optimization process. The enhancement in thermal performance results
in a rise in pressure drop and total annual costs. So, finding optimal dimensions of heat exchanger is a key stage in designing
process. In this paper, optimization has been done based on entropy generation minimization, where Cuckoo Algorithm aided
to reach better results. Three types of heat exchangers are designed for heat recovery system from a microturbine 180 KW. The
optimization process showed a decrease in entropy generation number up to 23%. Although, after optimization process the
pressure drops decrease between 8% to 17 %, based on the type of fins, the total volume of the heat exchanger increased. The
results show the possibility of saving energy up to 21% using this method.
Key words: Entropy Generation, Heat Recovery System, Optimization, Cuckoo Algorithm.
Introduction
A heat exchanger is a device to transfer thermal energy between two or more fluids, one comparatively hot and the other
comparatively cold. A special and important class of heat exchanger is used to achieve a very large heat transfer area per
volume. The compact heat exchangers, these devices have dense arrays of finned tubes or plates and are typically used when at
least one of the fluid is a gas , and is hence characterized by a small convection coefficient. Plate heat exchangers, finned tube
heat exchangers, and plate-fin heat exchangers are in the class of compact heat exchangers. The surface area density, | , which
is defined as the ratio of the heat transfer area to the volume of the heat exchangers, is often used to describe the compactness
of heat exchangers. The compact heat exchangers have a surface area density greater than about
2 3
600 / m m , or the hydraulic
diameter is smaller than about 6 mm operating in a gas stream.
To improve the heat transfer rate, the heat transfer area is increased by adding fins to heat exchanger. When a high
compactness is desirable, complex interrupted fin surfaces are preferred, such as offset strip fins, perforated fins, slit fins and
wavy fins. This type of fins prevents the formation of thick boundary layers and encourages flow destabilization. However, one
of the main drawbacks of the interrupted fin designs is pressure drop. In fact, the enhancement in thermal performance causes a
rise in pressure drop, which increases the load of pumping power. Consequently, the overall assessment of plat-fin heat
exchanger requires a trade-off between thermal performance and pressure drop. Entropy generation minimization (EGM)
method is based on this theory that a thermodynamically optimized system has the least irreversible or minimum entropy
generation in the system. This method was firstly introduced by Bejan et, al.(1982) as optimization tool in thermodynamic
systems for a broad range of engineering fields. The theory of EGM states that all real systems suffer their thermodynamic
imperfection due to heat transfer, fluid flow and mass transfer irreversibility. Therefore, the entropy generation can be used as
a measure of systems departure from reversibility. Culham and Muzychka (2000) used the EGM tools to optimization of a
plate fin heat sinks in electronics applications. Dealing with various geometric parameters, heat transfer rate and material
properties of heat sinks, the application of multi-parameter optimization is more productive than an analytical approach with
empirical equations and powerful numerical simulation which cannot simultaneously optimize more than two parameters.
Wen-Jei Yang et, al.(2002) studied the accuracy of this method and compared its results with numerical methods such as CFD
and reached this results that the EGM has acceptable performance. Although many researcher studied about this method and its
result, but there are scarce resources about the application of this method in mechanical design of a plate-fin heat exchanger. In
this study, it is designed a plate-fin heat exchanger for heat recovery in microturbine cycle. Mechanical design of heat
exchanger has been done based on sizing problem, and then its performance improved using the EGM method, which it is used
by new optimization algorthim, Cuckoo algorithm, to reach better performance. This algorithm was introduced in 2011 by
Ramin Rajabioun.

22. Engr. Tech. & Res.
Nomenclature
t
A : heat transfer area P: pressure
P
C : specific heat Re : Reynolds number
h
D : hydraulic diameter
gen
S

:entropy generation
f: friction factor T : temperature of fluids
h: convective coefficient

Greek symbols
t
H : tube height
: fluid density
j: Colburn factor
: dynamic viscosity
C
K :Contraction coefficient Subscripts
e
K : expansion coefficient h : hot stream
K :thermal conductivity c : cold stream
m: mass flow rate i : input
N
s
:entropy generation number o : output
NTU:number of transfer unit

23. Asadi
Model Development for Thermodynamical
Optimization
Consider a point (x, y) in a fluid engaged in convective
heat transfer, where the fluid element dXdY surrounding
this point is part of a considerably more complex
convective heat transfer arrangement. It is regarded the
small element dXdY as an open thermodynamic system
subjected to mass fluxes, energy transfer, and entropy
transfer interactions that penetrate the fixed control surface
formed by dXdY rectangle of Fig.(1).



Figure 1: The local generation of entropy in a flow with
convective heat transfer.
The element size is small enough so that the
thermodynamic state of the fluid inside the element may
be regarded as uniform ( Bejan et, al. 1996). However, the
thermodynamic state of the element may change with time.

Hence, based on this model , the entropy generation rate
per unit volume is:

( )
y
x
y
x
y
x
gen
x
x
y
y
x y
q
q
q dy
q dx
q
q y
x
S dxdy dy dx dy dx
T T
T T
T dx T dy
x y
s
s dx dx dx dy
x x x
s
s dy dy dy dx
y y y
s
s dy s dx dxdy
t
u
u
u

u

u u
c
c
+
+
c
c
''' = +
c c
+ +
c c
c c c | | | | | |
+ + + +
| | |
c c c
\ . \ . \ .
c | | | | | | c c
+ + + +
| | |
c c c
\ . \ . \ .
c
+
c
(1)
In this expression the first four terms account for the
entropy transfer associated with heat transfer, the next four
terms represent the entropy converted into and out of the
system, and the last term represents the time rate of
entropy accumulation in the dXdY volume (Bejan et, al.
1996). Using some assumptions the irreversibility due to
heat transfer is:
, ,
, ,
h o c o
gen P P
h i c i
h c
T T
S mC Ln mC Ln
T T
| | | |
= +
| |
\ . \ .

(2)
Where entropy changes associated with the frictional
pressure drops
( )
c h out in
P P
,

have not been included. For

Simplicity, consider a balanced counter flow arrangement
( ) 1 =
-
C in which the stream to stream temperature
difference and frictional pressure drops are not negligible.
So the entropy generation rate in this arrangement is:

, ,
, ,
, ,
, ,
h o c o
gen P P
h i c i
h c
h o c o
h c
h i c i
T T
S mC Ln mC Ln
T T
P P
m R Ln m R Ln
P P
| | | |
= +
| |
\ . \ .

(3)
Where the first two terms on the right represent the heat
transfer irreversibility and the last two terms account for
fluid friction. Thus, the entropy generation number
becomes.
( )
( )
2
, ,
, ,
1
h i c i
S
h i c i P c
c
P h
h
T T
R P
N
T T C P
R P
C P
c

| | A | |
= +
| |
\ .
\ .
| | A | |
+
| |
\ .
\ .
(4)
Where
, h i
T and
, c i
T are inlet temperatures. The heat
transfer irreversibility vanishes when the area is very large
( )
NTU or when the counter flow is isothermal due to
end conditions ( )
t = . Also, the fluid friction
irreversibility vanishes when the pressure drops on the two
sides of the surface are zero. Also, when both fluids are
unmixed the heat exchanger effectiveness is:
( )
0.22 * 0.78
*
1
1 exp NTU exp C .NTU 1
C
| |
(
c =
`
|

\ . )

(5)
In the equation of (4), the pressure drop is defined as,
( )
( )
, 2
,
2
,
1
,
, , 2
,
, ,
1 1
1
2
2
i h
C h h
o h
h
i h
i h i h h
h h e h
h m h o h
K
G
S
f k
A
P

o

( | |
+ + ( |
|
(
\ .
=
(
| |
(
+
|
( |
\ .
A (6)
Where
C
K and
e
K are contraction and expansion
coefficients respectively. Here, S and A are total heat
transfer area and frontal area. , f and G are also friction
factor, density and mass velocity respectively.
Cuckoo Algorithm
Figure of (2) demonstrates a flowchart of the proposed
algorithm. This algorithm, like any evolutionary algorithm,
starts with an initial population of cuckoos. These initial
cuckoos have some eggs in order to lay in some host birds
nests. Some of these eggs which are more similar to the
host birds eggs have this opportunity to grow up and
become a mature cuckoo. Host birds detect and kill the

24. Engr. Tech. & Res.
remained eggs. Where more eggs survive, the more profit
is gained. So, the position in which more eggs survive will
be the term that COA is going to optimize.
To solve an optimization problem, it is necessary that the
values of problem variables be formed as an array (Ramin
Rajabioun et, al. 2011). In Genetic and Particle Swarm
algorithms (GA & PSO), this array has been called
chromosome and particle position, but , here, it is called
habitat. In a
var
N -dimensional optimization problem, a
habitat is an array of
var
1 N , representing current living
position of cuckoo(Ramin Rajabioun et, al. 2011). This
array is:
( )
var
1 2 N
habitat= x ,x ,...,x

(7)
The profit of a habitat is obtained by evaluation of profit
function,
P
f .
( )
var
1 2 N
(habitat)= x ,x ,...,x
P P
f f

(8)
To start the optimization algorithm, a candidate habitat
matrix of size
var pop
N N is generated. Another habitat
of real cuckoos is that they lay eggs within a maximum
distance from their habitats (Ramin Rajabioun et, al. 2011)
. This maximum range has been called Egg Laying Radius
(ELR). So, ELR is:


(9)
( )
hi low
Number of current cuckoo's eggs
ELR= var -var
Total number of eggs

(9)

Figure 2: Cuckoo Algorithm Flowchart


Here, is an integer, supposed to handle the maximum
value of ELR (Ramin Rajabioun et, al. 2011). Also
hi
var ,
and
low
var are the upper and the low limit of variables
respectively.
Figure (2) denotes that each cuckoos starts laying eggs
randomly in the host birds nests. After egg laying process,
P% of all eggs (usually 10%), with less profit values, will
be detected and killed.

Figure 3: Random egg laying in ELR, central red star is
the initial habitat of the cuckoo with 5 eggs; pink stars are
the eggs new nest.
The host birds feed the rest of the eggs. Interestingly, only
one egg has the chance to grow in each nest, because of
her three times bigger body. She pushes other chicks and
eat more. As after couple of days the host birds own
chicks die due to hunger. When cuckoos become mature,
they live in their own society. In the time of the egg
laying, the young cuckoos immigrate to new environment,
where there are more similarity of eggs to host birds. After
the cuckoo groups are formed in different areas, the
society with best profit value is selected as the goal point
for other cuckoos to immigrate (Ramin Rajabioun et, al.
2011). When moving toward goal point, the cuckoos do
not fly all the way to the destination habitat. They only fly
a part of the way and also have a deviation. Here,
parameters of and help the cuckoos to search much
more positions in all environments.
( ) 0,1 : U

(10)
( ) , : U e e

(11)
Where e is a parameter which constraints the deviation
from goal habitat.


Figure 4: Immigration of a sample cuckoo toward goal
habitat.

Figure 5: Plate-Fin Heat Exchanger

25. Asadi
The next question is what to use for an iteration variable.
A very convenient variable is the mass velocity G for each
side of the heat exchanger, since it is easy to make a
reasonable initial estimate of both Gs. When
h
G and
c
G
are specified, the frontal areas HW and HD are fixed. The
complete dimensions of the heat exchanger are then
established when the volume V is determined. The
important note is that NTU is determined for the desired
heat exchanger effectiveness, based on the
min max
/ C C
and the heat exchanger efficiency. Here, a plate-fin heat
exchanger is designed for heat recovery. The operating
conditions are according to Table. (2)
Results and Discussion
Designing information before optimization process is
according to Table of (3). As it is evident, the fin type of
11.44-3/8 W has better performance compared with the
other types of fins, because for cold stream its pressure
drop is about 186% and 84% less than 11.5-3/8 W and
17.8-3/8 W fins. However, for hot stream, it is 54% and 50
% more respectively. In the optimization process the
variables are width, depth and height of the heat
exchanger. To limit search area it is better introducing the
variables in a restricted area. Figure of (6), (7) and (8)
show the optimization results for 11.44-3/8 W, 11.5-3/8 W
and 17.8-3/8 W.


Table 1 .Fin Geometric Properties
Plate
Spacing(mm)
Hydraulic
Diameter(mm)
Fin
Thickness(mm)
Wavelength(mm) Double Wave
Amplitude(mm)
Heat Transfer
Area/ Volume
Between
Plates
Fin
Area/Total
Area
11.44-3/8 W 10.49 3.23 0.152 9.53 1.97 1152 0.847
11.5-3/8 W 9.53 3.02 0.254 9.53 1.98 1138 0.822
17.8-3/8 W 10.49 2.12 0.152 9.53 1.97 1686 0.892


Table 2: Operating Conditions
Data Variables
6 Allowable pressure drop for hot side(%)
3 Allowable pressure drop for hot side(%)
321 Outlet gas temperature(K)
950 Inlet gas temperature(K)
875 Outlet air temperature(K)
175 Inlet air temperature(kK)
304 Inlet pressure for Air side(Kpa)

160.8 Inlet pressure for Gas side(Kpa)

0.685 Gas mass flow rate (kg/s)
0.662 Air mass flow rate(kg/s)




26. Engr. Tech. & Res.

Table 3: Designing Information Before Optimization Process
11.44-3/8 W 11.5-3/8 W 17.8-3/8 W
Air Gas Air Gas Air Gas
Re 22.4 40.1 18.5 40.2 16.1 31.5
j
0.019 0.018 0.02 0.02 0.016 0.016
f
0.13 0.12 0.13 0.12 0.09 0.09
( )
2
h / . w m k
7.03 16.5 6.8 17.8 6.3 15.6
f

0.81 0.73 0.82 0.70 0.82 0.75

o

0.83 0.77 0.85 0.75 0.83 0.77
( )
2
U w/m .k
3.98 3.98 4.03 4.03 3.64 3.64
NTU 17.24 17.24 17.24 17.24 17.24 17.24
( )
2
S m
474.59 474.59 413.82 413.82 575.3 575.3
567.7 567.7 525.16 525.16 882.36 882.36
( )
3
V m
0.836 0.836 0.788 0.788 0.652 0.652
0.457 0.457 0.396 0.396 0.468 0.468
( ) Width mm
750 750 630 630 580 580
( ) Depth mm
800 800 900 900 726 726
( ) Heith mm
1360 1360 1380 1380 1540 1540
( ) P Kpa
6.179 2.604 17.693 1.182 11.415 1.323
s
N
2.54 2.54 2.12 2.12 1.91 1.91


Figure 6: Optimization results for fin of 11.44-3/8 W.










27. Asadi










Figure 7: Optimization results for fin of 11.5-3/8 W.

Figure 8: Optimization results for fin of 17.8-3/8 W.
The cost function, here, is entropy generation number. This algorithm has an excellent performance compared with GA and
PSO algorithm, because after 40 habitats, maximum, has reached to the optimal value. Table.(4) gives the width , depth and
height of the heat exchanger for three types of fins ( After optimization process).




28. Engr. Tech. & Res.
Table: (4) Optimal Values of the Variables

11.44-3/8 W 11.5-3/8 W 17.8-3/8 W
Height(mm) 2112 2228 2560
Width(mm) 736 647 821
Depth(mm) 1524 1879 2113
Total volume(
3
m )
2.37 2.58 4.33

Table: (5) Designing Information after Optimization Process
11.44-3/8 W 11.5-3/8 W 17.8-3/8 W
Air Gas Air Gas Air Gas
Re 897 1000.8 1363.1 682 847 418
j
0.017 0.015 0.014 0.018 0.013 0.018
f
0.09 0.08 0.1 0.07 0.063 0.09
( )
2
h / . w m k
265.8 343.7 355.1 300.9 292.3 262.5
f

0.28 0.25 0.25 0.26 0.26 0.28

o

0.37 0.37 0.39 0.39 0.33 0.33
( )
2
U w/m .k
55.31 55.31 63.41 63.41 45.63 45.63
NTU 17.24 17.24 17.24 17.24 17.24 17.24
( )
2
S m
474.71 474.71 414.07 414.07 575.68 575.68
567.7 567.7 525.16 525.16 882.36 882.36
( )
3
V m
0.836 0.836 0.788 0.788 0.652 0.652
0.457 0.457 0.396 0.396 0.468 0.468
( ) Width mm
750 750 630 630 580 580
( ) Depth mm
800 800 900 900 726 726
( ) Heith mm
1360 1360 1380 1380 1540 1540
( ) P Kpa
-3
5.3610
-3
8.8610
-3
3.4210
-3
12.910
-3
2.2610
-3
10.510
s
N
1.67 1.67 1.18 1.18 1.13 1.13

Table of (4) and (5) denote information after optimization process. According to the equation of (4) entropy generation number
is only a function of pressure drop, because our problem is a sizing problem and inlet and outlets temperature are determined.
The results show that the cuckoo algorithm has decreased pressure dramatically in order to reach the optimal value of entropy
generation number. The important note is that, here, the cuckoo algorithm has not any effects on entropy generation arising
heat transfer, because inlet and outlet temperature are constant. So, there are some limitations for optimal value of the entropy
generation number. The other interesting note is that the optimal value of the Depth is much more than the Width value, since
the algorithm has increased the flow length in the hot side in order to set the pressure drops in the same range. The fan power
can be calculated by,
fan
f
m
Power = .P
.
(12)
Where,
f
is fan efficiency, and is assumed to be 0.8 for both streams. The results shows that saving energy about 98% in
operating costs is possible with this new method , Of course if there is not any limitations for total volume or on surface area.
However, if total volume and surface area be limited, we can use this this method to save energy between 20% to 80% based
on the dimensions of the heat exchangers.
References
Bejan, A. (1996) , Entropy Generation Minimization, CRC Press, New York.
Bejan, A. (1982), Entropy Generation Through Heat and Fluid Flow, John Wiley and Sons Ltd., New York.
Bejan, A. (1980) and Pfister P. A., Evaluation of Heat Transfer Augmentation Techniques, Letters in Heat and Mass
Transfer, Vol. 7, pp. 97-106.


29. Asadi

Culham, J. R. and Muzychka, Y. S. (2000),Optimization of Plate Fin Heat Sinks Using Entropy Generation Minimization, Inter
Society Conference on Thermal Phenomena,, pp. 8-15.
Wen-Jei Yang,(2002),Reliability of Heat Sink Optimization Using Entropy Generation Minimization, Thermophysics and
Heat Transfer Conference, Louis, Missouri, USA.
Ramin Rajabioun,(2011), Cuckoo Optimization Algorithm, Applied Soft Computing 11 (2011) 55085518.
Masoud Asadi and Dr R.H.Khoshkhoo, Investigation into radiation of a plate-fin heat exchanger with strip fins , Journal of
Mechanical Engineering Research, April 2013.
Masoud Asadi and Dr R.H.Khoshkhoo,Entropy Generation in a Plate-Fin Compact Heat Exchanger with Louvered Fins ,
International Journal Energy Engineering, , March2013.
Masoud Asadi and Nasrin Dindar Mehrabani, Minimization entropy generation into compact heat exchanger with Louvered
fins , Journal of Petroleum and Gas Engineering ,2013.
Masoud Asadi and Dr R.H.Khoshkhoo, Effects of mass flow rate in terms of pressure drop and heat transfer characteristics ,
Merit Research Journal of Environmental Science and Toxicology Vol. 1(1), February, 2013.