The heat exchanger is crucial to all systems and applications that use it. Researchers are primarily focused on improving this component’s thermal conductivity to improve its efficiency. This was achieved by using one or more of the following strategies: inserting tapes with various shapes and numbers, inserting rings of various shapes and spacing between each, and transforming a basic liquid into a nanoliquid by adding nanomaterials with high conductivity and ultra-small particle sizes. Different types of nanomaterials were added in varying concentrations. In earlier studies, it was found that every increase in heat transfer was accompanied by a pressure drop at both ends of the exchanger. The amount of heat transferred and the pressure drop are affected by many factors, such as the torsion tape ratio, the pitch of the ring, and whether the pitch faces the direction of flow or not. Heat transfer rates can also be impacted by factors such as the length and angle of the wings, how many rings and tapes there are, and whether the rings and tapes contain holes or wings. In addition, the Reynolds number, the type, conductivity, and size of nanomaterials, and the base fluid used in the nanofluid affect this. It is possible for the shape of the exchanger tube, as well as varying rates of rise, to introduce such impacts. In this study, the factors, costs, and benefits of using any technology to increase the efficiency of the heat exchanger are reviewed so that the user can make an informed decision about the technology to use.

In this study, it is proposed to generate electrical energy by recovering the waste heat of an annealing furnace (AF) in an iron and steel plant using combined cycles such as steam Rankine cycle (SRC), organic Rankine cycle (ORC), Kalina cycle (KC) and transcritical CO₂ cycle (t-CO₂). Instead of releasing the waste heat into the atmosphere, the waste heat recovery system (WHRS) discharges the waste heat into the plant’s low-temperature oxygen line for the first time, achieving a lower temperature and pressure in the condenser than conventional systems. The waste heat of the flue gas (FG) with a temperature of 1093.15 K from the reheat furnace was evaluated using four different cycles. To maximize power generation, the SRC input temperature of the proposed system was studied parametrically. The cycles were analyzed based on thermal efficiency and net output power. The difference in SRC inlet temperature is 221.6 K for maximum power output. The proposed system currently has a thermal efficiency and total power output of 0.19 and 596.6 kW, respectively. As an environmental impact, an emission reduction potential of 23.16 tons/day was achieved. In addition, the minimum power generation cost of the proposed system is $0.1972 per kWh.