Experimental and numerical thermo-hydraulic performance optimization of fin and tube heat exchanger using genetic algorithms

This study focuses on the multi-objective optimization of fin and tube heat exchangers to maximize the Thermal Performance Factor and minimize the Volume . A novel fin design is proposed and integrated onto the tube surfaces to enhance thermo-hydraulic performance. The numerical simulations were conducted using Computational Fluid Dynamics with the conjugate heat transfer method, while the optimization framework was established on modeFRONTIER using a Multi-Objective Genetic Algorithm (MOGA-II). The numerical model was validated against experimental data in this study and existing literature data. The optimization process investigated various fin parameters, (Dwing, Dring, αback,αfront and Gwing), alongside heat exchanger design parameters (ST and SL) and inlet velocity (Vinlet) including 0.3–10 m/s. A total of 1271 design points were evaluated, resulting in 998 feasible configurations and 24 distinct Pareto-optimal designs. The Pareto-optimal Design set yielded TPF values ranging from 1.09 to 1.66. The results highlight the typical trade-off between thermal performance and heat exchanger Volume . Higher TPF values generally correspond to larger volumes, with Design ID 1 achieving the maximum TPF (1.66) but also the largest volume. Conversely, designs with smaller volumes (Design IDs 22–24) exhibit lower TPF values (≈1.09–1.13). Even among designs with the same volume and inlet velocity, variations in fin geometry significantly affect thermal performance. Therefore, designs with higher TPF are preferable when thermal efficiency is the priority, while more compact designs are suitable when minimizing volume is the main goal. © 2026 Elsevier Ltd.