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Abstract
This study presents a comparative design optimization of cylindrical and spherical pressure vessels operating under high internal pressures and transient thermal gradients, common in high-temperature industrial systems such as nuclear reactors, chemical processing plants, and high-performance steam generators. Emphasis is placed on optimizing structural integrity, thermal stress mitigation, and material efficiency. Finite element analysis (FEA) is employed to simulate thermomechanical responses, and optimization algorithms are used to identify geometries and materials that balance mechanical strength, thermal resistance, and cost. The paper contributes to an informed selection process between cylindrical and spherical configurations by evaluating failure modes, stress distributions, and thermal response under dynamic conditions. The results suggest that spherical vessels, while structurally superior under pressure, can exhibit thermal gradients leading to local stress concentrations if not adequately insulated, whereas cylindrical vessels are more prone to longitudinal stress buildup but easier to manufacture and maintain.
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