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Incorporating baffles was demonstrably efficacious in augmenting the functionality of solar air heaters (SAHs). A duly validated mathematical model is formulated for SAHs with baffles, aimed at the optimization of baffle length (L b ). Our findings demonstrated that with air velocity ( v ) spanning from 0.5 to 3.0 m·s −1  and baffle length (L b ) varying between 150 and 750 mm, a discernible rise in pressure loss ensued. This phenomenon is ascribed to the extension of baffles, resulting in escalated air velocity and heightened vortex intensity. In the range of  v  = 0.5 ~ 3.0 m·s −1 , the collection efficiency evinced a marked surge by 4.61% to 11.32% when L b  traversed from 150 to 450 mm, while the collection efficiency tended to be constant as L b  exceeded 450 mm. A holistic evaluation of both pressure loss and heat collection efficiency culminates in the deduction that the pinnacle of operational effectiveness, measuring 60.78%, was attained at Lb = 600 mm and v = 3.0 m·s −1 . The economic scrutiny of baffled SAHs unveiled a Coefficient of Useful Energy (Cue) of a mere 0.057·kwh −1 , notably inferior to that resultingensuing from the incineration of fossil fuels under the conditions of v = 3.0 m·s −1  and Lb = 600 mm.

Optimization analysis of the length of baffles for solar air heaters based on CFD