Experimental 3E Assessment of a PLC-Controlled Solar Air Heater with Adjustable Baffle

This study presents an experimental 3E (energy–exergy–environmental) assessment of a PLC-controlled solar air heater (SAH) equipped with adjustable internal baffles. Unlike conventional passive systems, the proposed design enables active airflow regulation to maintain stable outlet temperatures of 54 °C and 60 °C, achieving rapid stabilization within 3–10 s under outdoor conditions. Experimental results show that increasing the baffle inclination significantly enhances convective heat transfer and thermal efficiency, while the friction factor remains primarily governed by the Reynolds number and exhibits minimal sensitivity to baffle angle. Exergy efficiency values remain relatively low (1.24–2.69%), and the sustainability index stays close to unity, reflecting the inherent thermodynamic limitations of low-temperature solar air heaters rather than deficiencies in system design. A regression-based airflow velocity model is developed to support fan-speed optimization and to clarify the trade-off between thermal enhancement and auxiliary power demand. Long-term projections based on regional solar data indicate that the proposed SAH can deliver approximately 20–22 MWh of useful heat and mitigate nearly 9 tons of CO2 emissions over a 20-year operational lifetime. Overall, the results demonstrate that PLC-assisted dynamic baffle control provides a flexible and effective approach for improving the performance and operational stability of solar air heaters for low-temperature drying applications.