Entropy Generation Analysis of a Heat Exchanger for Precision Applications

Process heating for sensitive fluids requires a sophisticated balance of efficiency and thermal control. This study assesses the efficiency of a singular active-surface flow box delivering high-precision, volumetric energy transport. Entropy generation analysis coupled with conjugate heat transfer can be effectively conducted using three-dimensional CFD to monitor the local irreversibilities stemming from direct contact with the active surface (heat transfer) and macro-steady flow structures (viscous dissipation). The entropy generation metric proposed, based on a Brinkman number, demonstrates that the global entropy generated grows less than linearly with the applied thermal power, while only a slight decrease is found with the increasing flow rate, for the two fluids examined. We conclude that integrating entropy generation analysis within a CFD framework is a robust tool for optimizing heaters for precision processing. For sensitive fluids such as liquid foods, this methodology is particularly valuable, as it directly links thermodynamic efficiency to quality retention by limiting excessive local temperatures. This research advances the development of entropy-informed thermo-fluid systems, offering a clear pathway for the design of high-performance, precision heating devices.