This study investigated the influence of BFFSP on the thermohydraulic performance of a SATHEC(s) using a novel computational approach. The novelty lies in the detailed exploration of the interplay between BFFSP, MFRT, and key performance parameters. Unlike prior studies, which often focus on a limited range of operating conditions, this work employs a comprehensive parametric analysis encompassing two BFFSPs (95 mm and 125 mm) and four MFRTs (0.1, 0.3, 0.5, and 0.7 kg/h). This extensive analysis provides a deeper understanding of the trade-off between the HTRFR enhancement and PDP associated with the BFFSP across a wider range of operating conditions. This investigation leverages the power of computational fluid dynamics (CFD) simulations for high-fidelity analysis. ANSYS Fluent, a widely recognized commercial CFD software package, was used as a computational platform. A three-dimensional steady-state model of HEXR geometry was established. The cold fluid was modeled as water, and the hot fluid was modeled as water. The selection of appropriate turbulence models is crucial for accurate flow simulations within the complex geometry of HEXR. This study incorporates a well-established two-equation turbulence model to effectively capture turbulent flow behavior. The governing equations for mass, momentum, and energy conservation were solved numerically within the CFD framework. Convergence criteria were meticulously established to ensure the accuracy and reliability of the simulation results. BFFs are crucial components in HEXRs as they promote fluid mixing and turbulence on the HTRFR surface, thereby enhancing HTRFR. This study explores the interplay between BFFSP and HTRFR effectiveness. It is hypothesized that a larger BFFSP (125 mm) might lead to a higher HTC owing to the increased fluid mixing. However, the potential drawbacks of the increased PDP due to the flow restriction also need to be considered. The PDP across the HEXR is a critical parameter that affects pumping costs and overall system yield. This study investigates the impact of BFFSP on the PDP. It is expected that a larger BFFSP (125 mm) will result in a higher PDP, owing to the increased resistance to fluid flow. Here, we aim to quantify the trade-off between enhanced HTRFR and increased PDP associated with different BFFSPs. The optimal design of an HEXR seeks a balance between achieving a high HTRFR rate and minimizing pressure losses. HTRPD, a metric combining both HTC and PDP, was employed to evaluate the thermohydraulic performance. We hypothesized that a specific BFFSP might offer a superior HTRPD, indicating an optimal balance between HTRFR effectiveness and PDP for the investigated HEXR geometry and operating conditions. CFD simulations were conducted using ANSYS Fluent to analyze the effects of BFFSP and MFRT on the HTC, PDP, and HTRPD. The simulations employed a commercially available HEXR geometry with water as the cold and hot fluid. The results are presented and discussed to elucidate the relationships between the BFFSP, MFRT, and key performance parameters of the HEXR. This study provides valuable insights into the influence of BFFSP on the thermohydraulic performance of HEXRs. The findings can aid in optimizing the HEXR design by identifying the BFFSP that offers the best compromise between HTRFR enhancement and PDP for specific operating conditions. The results contribute to the knowledge base of HEXR design and optimization, potentially leading to improved yield in various industrial applications. The results indicate that a larger BFFSP (125 mm) leads to higher outlet temperatures but also results in a higher PDP compared to the 95 mm design. Conversely, the 95 mm BFFSP exhibits a lower PDP but achieves a lower HTC. In terms of thermohydraulic performance, as indicated by HTRPD, the 95 mm BFFSP with the lowest MFRT (0.1 kg/h) achieved the highest value, surpassing the 125 mm design by 19.81%. This suggests that a 95 mm BFFSP offers a better trade-off between HTRFR effectiveness and pressure loss, potentially improving the overall HEXR performance. Full article