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<p>Polymeric heat exchangers are alternatives to traditionally made steel heat exchangers to reduce corrosion and increase longevity. Chemical industries typically employ polymer-based heat exchangers to heat and cool concentrated acids as well as alkaline solutions. Primarily, polyethylene terephthalate glycol (PETG) exhibits excellent chemical inertness and is&#xa0;resistant to corrosion, thereby reducing the fouling factor. However, it has low thermal conductivity. This work enables the fused deposition additive manufacturing (AM) technique to produce PETG-based polymer heat exchangers (PHE) with gyroid structures to achieve a high heat transfer rate by reducing the wall thickness and increasing the surface area of the material. By varying the process parameters, such as volume flow rate and the geometry of the heat exchanger, the heat transfer coefficient (HTC) is enhanced by 287.81% at 1 lpm compared to conventional double pipe heat exchangers. On comparing the effectiveness of the proposed heat exchanger with the conventional one, the enhancement is 240.37% at 1 lpm. Validation studies using CFD were also done and compared with experimental results, which are found to be in agreement. Hot fluid temperature drops by 16&#xa0;°C. The thermal enhancement factor of the proposed heat exchanger is also very high (3.40) when compared to the other exchangers. This leads to the compactification of the&#xa0;heat exchanger.</p>

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Comprehensive investigation of heat transfer performance in polymer heat exchangers with gyroid layers: a definitive experimental and computational study

  • 期刊论文

  • 发表日期：

    2026年1月10日

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  • Selvan Pugalenthi,
  • Suraboopathy Karuppasamy

摘要

Polymeric heat exchangers are alternatives to traditionally made steel heat exchangers to reduce corrosion and increase longevity. Chemical industries typically employ polymer-based heat exchangers to heat and cool concentrated acids as well as alkaline solutions. Primarily, polyethylene terephthalate glycol (PETG) exhibits excellent chemical inertness and is resistant to corrosion, thereby reducing the fouling factor. However, it has low thermal conductivity. This work enables the fused deposition additive manufacturing (AM) technique to produce PETG-based polymer heat exchangers (PHE) with gyroid structures to achieve a high heat transfer rate by reducing the wall thickness and increasing the surface area of the material. By varying the process parameters, such as volume flow rate and the geometry of the heat exchanger, the heat transfer coefficient (HTC) is enhanced by 287.81% at 1 lpm compared to conventional double pipe heat exchangers. On comparing the effectiveness of the proposed heat exchanger with the conventional one, the enhancement is 240.37% at 1 lpm. Validation studies using CFD were also done and compared with experimental results, which are found to be in agreement. Hot fluid temperature drops by 16 °C. The thermal enhancement factor of the proposed heat exchanger is also very high (3.40) when compared to the other exchangers. This leads to the compactification of the heat exchanger.