Computational Fluid Dynamics–Response Surface Methodology Optimization of Hydrothermal and Entropy Performance in Porous Cassini Oval Annuli

ABSTRACT Forced convection and entropy generation through a complex geometry like Cassini oval annuli play a significant role in many applied thermal engineering systems. The novel feature of the present work is a multi‐objective and multi‐response optimal design of the hydrothermal and entropy performance in a porous Cassini oval annular pipe. This approach integrates the response surface methodology (RSM) CFD simulation for evaluating different key design parameters. The variables studied are the inner twisted pipe pitches (0 ≤ P ≤ 1.5), aspect ratios (0.08 ≤ AR ≤ 0.2), porosity (0.1 ≤ ɛ ≤ 0.9), and pore density (5 ≤ PPI ≤ 35) with different Reynolds numbers (50 ≤ Re ≤ 250). These parameters impact heat transfer rate, fluid mixing, and pressure drop. Optimization results indicate that low inner twisted pipe pitch ( p = 0.5), low aspect ratio (AR = 0.08), low pore per inch (PPI = 5), and high porosity ( ɛ = 0.9) are favorable for enhancing hydrothermal performance (NuE = 12.23 and PEC = 3.069) with moderate entropy generation (EG = 0.940). Consequently, this study introduces a useful procedure for optimizing the hydrothermal and thermodynamic performance of forced convection in porous Cassini oval annular pipe cooling systems.