Evaluation and heat transfer augmentation of a PV/T unit through parametric baffle installment: Data-driven modeling and swarm implementation

Thermal management remains a critical challenge in photovoltaic/thermal (PV/T) systems, as excessive heat buildup adversely affects electrical efficiency and system longevity. This study introduces a novel optimization framework for enhancing heat transfer in water-based PV/T systems through strategically designed circular baffles. Unlike previous studies that employed simple geometric variations, we develop a comprehensive methodology integrating computational fluid dynamics with Response Surface Methodology and Multi-Objective Particle Swarm Optimization to systematically analyze baffle angle (60°–360°), outer radius (12–22 mm), and Reynolds number (100–800) effects. Our approach reveals that increasing baffle angle to 360° enhances the Nusselt number ratio by 8.2 % through the generation of organized secondary vortices, while elevating Reynolds number to 800 boosts heat transfer by 617 %. The developed surrogate models achieve exceptional predictive accuracy (R2 > 0.96), enabling rapid design optimization. The optimization identifies configurations that balance thermal enhancement with hydraulic penalties, with Run 12 (Re = 450) achieving a Performance Evaluation Criterion of 1.02, representing a 6.4 % thermal improvement with manageable flow resistance. This work provides a validated, systematic framework for optimizing baffled PV/T systems, offering practical design guidelines for enhanced solar energy harvesting.