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Advancements and Future Prospects of Heat Exchangers in Thermal and Energy Management

A special issue of Energies (ISSN 1996-1073). This special issue belongs to the section "J: Thermal Management".

Deadline for manuscript submissions: 19 December 2025 | Viewed by 1532

Special Issue Editors

Dr. Fabio Bozzoli

E-Mail Website
Guest Editor
Department of Engineering and Architecture, University of Parma, Parma, Italy
Interests: inverse heat transfer problems; infrared thermography; heat exchangers; heat pipes; forced convection
Prof. Dr. Marcelo José Colaço

E-Mail Website
Guest Editor
Department of Mechanical Engineering, Federal University of Rio de Janeiro, Rio de Janeiro, Brazil
Interests: heat transfer; thermal conductivity; heat conduction

Special Issue Information

Dear Colleagues,

The evolution of heat exchangers represents a basis for advancing thermal and energy management systems across various industrial sectors. These devices are indispensable in enhancing energy efficiency, reducing environmental impact, and enabling innovations in diverse applications. Heat exchangers continue to undergo significant advancements from conventional climate control systems to innovative thermal management solutions in electric vehicles, aerospace, renewable energy systems, industrial processes, and electronic devices. This progress is driven by innovations in materials, computational modeling, manufacturing techniques, and integration with smart control systems. Prospects include further miniaturization, enhanced heat transfer capabilities, integration with renewable energy sources, and adaptation to emerging technologies like artificial intelligence for predictive maintenance and optimization. This Special Issue aims to explore and disseminate the latest breakthroughs in heat exchanger technology.

Specific topics of interest for publication in this Special Issue include, but are not limited to, the following:

  • Design, scale-up, and modeling;
  • Predictive maintenance;
  • Heat transfer enhancement;
  • Experimental test techniques;
  • Optimized geometries;
  • Material innovations;
  • Smart devices;
  • Heat pipes;
  • Sustainability and environmental impact;
  • Waste heat recovery;
  • Miniaturization and compact designs;
  • Advanced manufacturing techniques;
  • Artificial intelligence and machine learning;
  • Electrical and thermal storage;
  • Sophisticated applications of heat exchangers.

Dr. Fabio Bozzoli
Prof. Dr. Marcelo José Colaço
Guest Editors

Manuscript Submission Information

Manuscripts should be submitted online at www.mdpi.com by registering and logging in to this website. Once you are registered, click here to go to the submission form. Manuscripts can be submitted until the deadline. All submissions that pass pre-check are peer-reviewed. Accepted papers will be published continuously in the journal (as soon as accepted) and will be listed together on the special issue website. Research articles, review articles as well as short communications are invited. For planned papers, a title and short abstract (about 100 words) can be sent to the Editorial Office for announcement on this website.

Submitted manuscripts should not have been published previously, nor be under consideration for publication elsewhere (except conference proceedings papers). All manuscripts are thoroughly refereed through a single-blind peer-review process. A guide for authors and other relevant information for submission of manuscripts is available on the Instructions for Authors page. Energies is an international peer-reviewed open access semimonthly journal published by MDPI.

Please visit the Instructions for Authors page before submitting a manuscript. The Article Processing Charge (APC) for publication in this open access journal is 2600 CHF (Swiss Francs). Submitted papers should be well formatted and use good English. Authors may use MDPI's English editing service prior to publication or during author revisions.

Keywords

  • heat exchangers
  • thermal management
  • efficiency
  • heat transfer enhancement
  • scale-up
  • optimization
  • heat pipes
  • thermal storage
  • designs
  • fouling

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Published Papers (3 papers)

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Research

29 pages, 8244 KiB  
Article
Enhanced Passive Thermal Management for Electric Vehicle Batteries Using a 3D Pulsating Heat Pipe
by Luca Cattani, Federico Sacchelli and Fabio Bozzoli
Energies 2025, 18(9), 2306; https://doi.org/10.3390/en18092306 - 30 Apr 2025
Viewed by 100
Abstract
This study experimentally analyzes the performance of a passive thermal management system using a three-dimensional (3D) pulsating heat pipe (PHP) designed for pouch cell batteries in electric vehicles. The term “3D” refers to the complex spatial arrangement of the PHP, which features multiple [...] Read more.
This study experimentally analyzes the performance of a passive thermal management system using a three-dimensional (3D) pulsating heat pipe (PHP) designed for pouch cell batteries in electric vehicles. The term “3D” refers to the complex spatial arrangement of the PHP, which features multiple interconnected loops arranged in three dimensions to maximize heat dissipation efficiency and improve temperature uniformity around the battery pack. Lithium-ion pouch cells are increasingly favored for compact and lightweight battery packs but managing their heat generation is crucial to maintaining efficiency and preventing failure. This research investigates the operational parameters of a 3D PHP by testing two working fluids (R134a and Opteon-SF33), three filling ratios (30%, 50%, and 80%), and various condenser conditions (natural and forced convection at 5 °C, 20 °C, and 35 °C). The effectiveness of the PHP was tested using simulated battery discharge cycles, with power inputs ranging from 5 to 200 W. The results show that the 3D PHP significantly improves battery thermal management. Additionally, Opteon-SF33, an environmentally friendly refrigerant, offers excellent heat transfer properties, making 3D PHP with this fluid a promising passive cooling solution for electric vehicle batteries. Full article
(This article belongs to the Special Issue Advancements and Future Prospects of Heat Exchangers in Thermal and Energy Management)
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13 pages, 6774 KiB  
Article
Predictive Modeling of Textile Heat Sinks for Enhanced Thermal Management in Space and Military Applications
by Michal Frydrysiak and Piotr Kosobudzki
Energies 2025, 18(7), 1744; https://doi.org/10.3390/en18071744 - 31 Mar 2025
Viewed by 244
Abstract
This paper presents the research and numerical modeling of heat flow through a textile heat sink (THS). The aim of this research is to create a numerical model of a THS that not only simulates the thermal behavior of knitted fabrics, which are [...] Read more.
This paper presents the research and numerical modeling of heat flow through a textile heat sink (THS). The aim of this research is to create a numerical model of a THS that not only simulates the thermal behavior of knitted fabrics, which are used to construct a THS, but also serves as a predictive tool for the heat flow coming from different devices, thus increasing thermal management safety. By integrating modeling tools with textile engineering, this study contributes valuable insights to the development of effective passive cooling solutions for textronics applications, e.g., in thermal management in the military or air space sectors. THS is a support tool for multilayer insulation (MLI) blankets in space satellites, used to maintain the insulation performance of MLI to retain the extremely low temperature of satellite sensors or fuel tanks. The textile radiator made of spacer knitted 3D fabric consists of monofilament yarns covered with aluminum. THS samples were made on the HD 6/20-65 EL machine of Karl Mayer, with the calibration number E12. Numerical modeling was performed using ANSYS software. The numerical simulations of the temperature gradient presented the heat flow for source temperatures of 50 °C and 70 °C for different values of air velocity. Full article
(This article belongs to the Special Issue Advancements and Future Prospects of Heat Exchangers in Thermal and Energy Management)
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34 pages, 14728 KiB  
Article
Physics-Based Modelling of Plate-Fin Heat Exchangers
by Mattia Grespan, Adriano Leonforte, Luigi Calò, Marco Cavazzuti and Diego Angeli
Energies 2025, 18(3), 495; https://doi.org/10.3390/en18030495 - 22 Jan 2025
Cited by 1 | Viewed by 663
Abstract
Aluminium plate-fin heat exchangers are widely used in automotive, aerospace, and other industrial applications. Extensive research has been conducted on these coolers, yet accurate predictive tools for their thermo-hydraulic performance are still lacking, due to the wide variety of geometric parameters and working [...] Read more.
Aluminium plate-fin heat exchangers are widely used in automotive, aerospace, and other industrial applications. Extensive research has been conducted on these coolers, yet accurate predictive tools for their thermo-hydraulic performance are still lacking, due to the wide variety of geometric parameters and working fluids involved. This work proposes an original approach based purely on physical principles and established models, combining detailed numerical models for the extended surfaces and manifolds, with global models aimed at accurately evaluating overall head losses and heat transfer rates in plate-fin heat exchangers. Extended surfaces are studied by means of computational models of unitary fin modules under fully developed flow conditions. Entrance effects are analysed through dedicated numerical models. Numerical results on extended surfaces are extended to whole heat exchangers by global models for heat transfer and head losses, based on the ε−NTU method and the Darcy–Weisbach equation, respectively. The proposed approach is presented and validated through the analysis of a case study comprising several heat exchangers featuring different geometries and working fluids. Numerically derived heat transfer rates and head losses are compared with experimental data showing maximum deviations of ±20% for most of the tested configurations, highlighting the strength of the proposed modelling methodology. Full article
(This article belongs to the Special Issue Advancements and Future Prospects of Heat Exchangers in Thermal and Energy Management)
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