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A thermal model is developed for analysing the influences of arc rib fin arrangement and length of absorber plate on the heat transfer characteristics of a solar air heater. The arc rib fin arrangement is designed by varying the fin relative roughness height ratio (e/D_e) in the absorber plate. Solar air heater with fixed arc rib fin configuration with e/D_e (0.0422) and variable arc rib fin configuration with two different relative roughness height ratios of e/D_e (0.0422 and 0.0541) are modelled. The influence of absorber plate length (1 and 2 m) on the solar air heater performance is compared with the configurations mentioned above at various mass flow rates of air (0.02 kgs⁻¹ to 0.06 kgs⁻¹). The outlet air temperature of solar air heater, mean absorber plate temperature, heat transfer characteristics (Nusselt number and frictional factor), pressure drop, thermo-hydraulic performance parameter, efficiencies (thermal, effective …