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Multiphysics CFD and Electrochemical Assessment of Silicon Carbide (SiC) Heat Exchangers for Corrosive Waste-heat Recovery in Process Industries
Research Article  ·  Published: 16 June 2026
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International Journal of Thermo-Fluid Systems and Sustainable Energy
Volume 2, Issue 2, 2026: 81-100
Research Article Open Access

Multiphysics CFD and Electrochemical Assessment of Silicon Carbide (SiC) Heat Exchangers for Corrosive Waste-heat Recovery in Process Industries

by
Samuel Oliver Effiom Samuel Oliver Effiom 1 * ORCID
Maria Kaka Etete Enoh Maria Kaka Etete Enoh 1 ORCID
Ukeme Enoh Akpan Ukeme Enoh Akpan 1
Precious-Chibuzo Effiom Precious-Chibuzo Effiom 2 ORCID
Fidelis Ibiang Abam Fidelis Ibiang Abam 2 ORCID
1 Department of Mechanical Engineering, University of Cross River State, Calabar 540281, Nigeria
2 Faculty of Engineering and Technology, University of Calabar, Calabar 540271, Nigeria
* Corresponding Author: Samuel Oliver Effiom, [email protected]
Volume 2, Issue 2
Volume 2, Issue 2 2026
Received: 14 May 2026 Accepted: 11 June 2026 Published: 16 June 2026 CrossMark
Download PDF 6.98 MB Cite Metrics
DOI: 10.62762/IJTSSE.2026.236790
ARK: ark:/57805/ijtsse.2026.236790

Article Information

Published in International Journal of Thermo-Fluid Systems and Sustainable Energy
Volume/Issue Volume 2, Issue 2, 2026
Pages 81-100

Abstract

Corrosive waste-heat recovery systems suffer material degradation, performance loss and high maintenance when conventional metallic heat exchangers face chloride-, carbonate- and sulfur-bearing condensates. This study presents a multiphysics CFD-electrochemical assessment of silicon carbide (SiC) for heat exchangers, via a 3D shell-and-tube model in COMSOL Multiphysics coupling turbulent flow, conjugate heat transfer, species transport and electrochemical corrosion. The thermal model considered high-pressure ammonia (tube side) and pressurized water (shell side); the corrosion model represented a flue-gas condensate/electrolyte containing Cl\(^-\), NH\(_4^+\), HCO\(_3^-\), CO\(_3^{2-}\), HSO\(_3^-\)/SO\(_4^{2-}\) and NO\(_3^-\) at the wetted surface, with electrochemical behavior resolved via secondary/tertiary current-distribution (Nernst–Planck/Butler–Volmer) formulations. Base-case results gave heat-transfer coefficients of 620 vs. 420 W m\(^{-2}\) K\(^{-1}\) (47.6% improvement), a pressure-drop reduction from 2.63 to 1.92 Pa, and a thermal–hydraulic performance factor of 1.64 (SiC vs. stainless steel). Electrochemical simulations predicted lower localized current density and corrosion flux for SiC than stainless steel under the same electrolyte chemistry, though as model-based comparative indicators rather than validated corrosion rates. Sensitivity screening showed SiC thermal conductivity, wall roughness, electrolyte conductivity and chloride concentration affect the magnitude of improvement, though the base-case trend remained favorable. The study offers a verified, literature-benchmarked framework for preliminary material screening, identifying experimental corrosion testing, temperature-dependent properties and thermo-electrochemical coupling as next steps before industrial adoption.

Graphical Abstract

Multiphysics CFD and Electrochemical Assessment of Silicon Carbide (SiC) Heat Exchangers for Corrosive Waste-heat Recovery in Process Industries

Keywords

Silicon carbide CFD electrochemical corrosion waste-heat recovery shell-and-tube heat exchanger Nernst–Planck transport

Data Availability Statement

Data will be made available on request.

Funding

This work was supported without any funding.

Conflicts of Interest

The authors declare no conflicts of interest.

AI Use Statement

The authors declare that no generative AI was used in the preparation of this manuscript.

Ethical Approval and Consent to Participate

Not applicable.

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APA Style
Effiom, S. O., Enoh, M. K. E., Akpan, U. E., Effiom, P. C., & Abam, F. I. (2026). Multiphysics CFD and Electrochemical Assessment of Silicon Carbide (SiC) Heat Exchangers for Corrosive Waste-heat Recovery in Process Industries. International Journal of Thermo-Fluid Systems and Sustainable Energy, 2(2), 81-100. https://doi.org/10.62762/IJTSSE.2026.236790
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TY  - JOUR
AU  - Effiom, Samuel Oliver
AU  - Enoh, Maria Kaka Etete
AU  - Akpan, Ukeme Enoh
AU  - Effiom, Precious-Chibuzo
AU  - Abam, Fidelis Ibiang
PY  - 2026
DA  - 2026/06/16
TI  - Multiphysics CFD and Electrochemical Assessment of Silicon Carbide (SiC) Heat Exchangers for Corrosive Waste-heat Recovery in Process Industries
JO  - International Journal of Thermo-Fluid Systems and Sustainable Energy
T2  - International Journal of Thermo-Fluid Systems and Sustainable Energy
JF  - International Journal of Thermo-Fluid Systems and Sustainable Energy
VL  - 2
IS  - 2
SP  - 81
EP  - 100
DO  - 10.62762/IJTSSE.2026.236790
UR  - https://www.icck.org/article/abs/IJTSSE.2026.236790
KW  - Silicon carbide
KW  - CFD
KW  - electrochemical corrosion
KW  - waste-heat recovery
KW  - shell-and-tube heat exchanger
KW  - Nernst–Planck transport
AB  - Corrosive waste-heat recovery systems suffer material degradation, performance loss and high maintenance when conventional metallic heat exchangers face chloride-, carbonate- and sulfur-bearing condensates. This study presents a multiphysics CFD-electrochemical assessment of silicon carbide (SiC) for heat exchangers, via a 3D shell-and-tube model in COMSOL Multiphysics coupling turbulent flow, conjugate heat transfer, species transport and electrochemical corrosion. The thermal model considered high-pressure ammonia (tube side) and pressurized water (shell side); the corrosion model represented a flue-gas condensate/electrolyte containing Cl\(^-\), NH\(_4^+\), HCO\(_3^-\), CO\(_3^{2-}\), HSO\(_3^-\)/SO\(_4^{2-}\) and NO\(_3^-\) at the wetted surface, with electrochemical behavior resolved via secondary/tertiary current-distribution (Nernst–Planck/Butler–Volmer) formulations. Base-case results gave heat-transfer coefficients of 620 vs. 420 W m\(^{-2}\) K\(^{-1}\) (47.6% improvement), a pressure-drop reduction from 2.63 to 1.92 Pa, and a thermal–hydraulic performance factor of 1.64 (SiC vs. stainless steel). Electrochemical simulations predicted lower localized current density and corrosion flux for SiC than stainless steel under the same electrolyte chemistry, though as model-based comparative indicators rather than validated corrosion rates. Sensitivity screening showed SiC thermal conductivity, wall roughness, electrolyte conductivity and chloride concentration affect the magnitude of improvement, though the base-case trend remained favorable. The study offers a verified, literature-benchmarked framework for preliminary material screening, identifying experimental corrosion testing, temperature-dependent properties and thermo-electrochemical coupling as next steps before industrial adoption.
SN  - 3069-1877
PB  - Institute of Central Computation and Knowledge
LA  - English
ER  -
BibTeX Format
Compatible with LaTeX, BibTeX, and other reference managers
@article{Effiom2026Multiphysi,
  author = {Samuel Oliver Effiom and Maria Kaka Etete Enoh and Ukeme Enoh Akpan and Precious-Chibuzo Effiom and Fidelis Ibiang Abam},
  title = {Multiphysics CFD and Electrochemical Assessment of Silicon Carbide (SiC) Heat Exchangers for Corrosive Waste-heat Recovery in Process Industries},
  journal = {International Journal of Thermo-Fluid Systems and Sustainable Energy},
  year = {2026},
  volume = {2},
  number = {2},
  pages = {81-100},
  doi = {10.62762/IJTSSE.2026.236790},
  url = {https://www.icck.org/article/abs/IJTSSE.2026.236790},
  abstract = {Corrosive waste-heat recovery systems suffer material degradation, performance loss and high maintenance when conventional metallic heat exchangers face chloride-, carbonate- and sulfur-bearing condensates. This study presents a multiphysics CFD-electrochemical assessment of silicon carbide (SiC) for heat exchangers, via a 3D shell-and-tube model in COMSOL Multiphysics coupling turbulent flow, conjugate heat transfer, species transport and electrochemical corrosion. The thermal model considered high-pressure ammonia (tube side) and pressurized water (shell side); the corrosion model represented a flue-gas condensate/electrolyte containing Cl\(^-\), NH\(\_4^+\), HCO\(\_3^-\), CO\(\_3^{2-}\), HSO\(\_3^-\)/SO\(\_4^{2-}\) and NO\(\_3^-\) at the wetted surface, with electrochemical behavior resolved via secondary/tertiary current-distribution (Nernst–Planck/Butler–Volmer) formulations. Base-case results gave heat-transfer coefficients of 620 vs. 420 W m\(^{-2}\) K\(^{-1}\) (47.6\% improvement), a pressure-drop reduction from 2.63 to 1.92 Pa, and a thermal–hydraulic performance factor of 1.64 (SiC vs. stainless steel). Electrochemical simulations predicted lower localized current density and corrosion flux for SiC than stainless steel under the same electrolyte chemistry, though as model-based comparative indicators rather than validated corrosion rates. Sensitivity screening showed SiC thermal conductivity, wall roughness, electrolyte conductivity and chloride concentration affect the magnitude of improvement, though the base-case trend remained favorable. The study offers a verified, literature-benchmarked framework for preliminary material screening, identifying experimental corrosion testing, temperature-dependent properties and thermo-electrochemical coupling as next steps before industrial adoption.},
  keywords = {Silicon carbide, CFD, electrochemical corrosion, waste-heat recovery, shell-and-tube heat exchanger, Nernst–Planck transport},
  issn = {3069-1877},
  publisher = {Institute of Central Computation and Knowledge}
}

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International Journal of Thermo-Fluid Systems and Sustainable Energy
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