Optimized Heat Exchanger Design for Waste Heat Recovery in Industrial Gas Turbine Systems

Abstract Industrial gas turbines generate large amounts of waste heat that often go unrecovered, resulting in energy losses and reduced system efficiency. Traditional heat exchangers used for waste heat recovery are typically bulky, inefficient, and prone to high-pressure drops. This creates a need for an optimised, compact, and efficient heat exchanger design that can operate reliably in high-temperature, high-flow conditions. The objective of this study is to develop a high-performance heat exchanger that maximises thermal recovery, minimises pressure loss, and enhances overall energy utilisation while maintaining structural integrity and reducing operational costs. The study follows a structured approach to develop an optimised heat exchanger for industrial gas turbines. It begins with data collection and analysis of turbine exhaust and existing exchanger performance to identify key inefficiencies. Conceptual designs are created to enhance heat recovery and reduce pressure loss. Computational simulations and Data-Driven surrogate modelling optimise the thermal performance of the heat exchanger. A physical prototype is fabricated and tested under realistic conditions, with Digital Twin Testing enabling real-time monitoring.