Heat exchangers have the potential for various engineering applications, and their performance is enriched by surface modification. The proposed system enriches the heat exchanger’s performance by adapting a peened stainless steel (SS) surface blasted with copper, grinding, sand, and iron. The influences peened SS surface modified with a copper blast, grinding, sandblast, and iron blast on the surface morphology of shell and tube heat exchanger surface (STHE) is analyzed via tungsten heated cathode electron gun featured scanning electron microscope and observed coarse grain surface. The SS surface featured STHE performance is experimentally evaluated by different flow rates (30, 60, 90, and 120 L/min) underwater fluid medium functioned by the temperature ranges of 25–75°C and its results are compared with computational fluid dynamic (CFD)/heat transfer research (HTRI) analyzed results. The 60 L/min flow rate was spotted as an optimum value for both shell and tube side reasons. The STHE is operated with a 60 L/min flow rate under the different peened surfaces and evaluated its Stanton number, Nusselt number, logarithmic mean temperature difference (LMTD), overall heat transfer coefficient, number of transfer units (NTU), effectiveness, and exergy efficiency. The iron blasted SS peened surface was observed to have better SHTE performance like Stanton number (0.0012), Nusselt number (2180), reduced LMTD of 31°C, improved overall heat transfer co-efficient of 2400 W/(m2∙K), better NTU of 0.5532, good effectiveness value of 0.451 62, and hiked exergy efficiency of 10% respectively.
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