Modeling of plate heat exchangers with generalized configurations

A mathematical model is developed in algorithmic form for the steady-state simulation of gasketed plate heat exchangers with generalized configurations. The configuration is defined by the number of channels, number of passes at each side, fluid locations, feed connection locations and type of channel-flow. The main purposes of this model are to study the configuration influence on the exchanger performance and to further develop a method for configuration optimization. The main simulation results are: temperature profiles in all channels, thermal effectiveness, distribution of the overall heat transfer coefficient and pressure drops. Moreover, the assumption of constant overall heat transfer coefficient is analyzed.     

Comprehensive comparison of small-scale natural gas liquefaction processes using brazed plate heat exchangers

The brazed plate heat exchanger (BPHE) has some advantages over the plate-fin heat exchanger (PFHE) when used in natural gas liquefaction processes, such as the convenient installation and transportation, as well as the high tolerance of carbon dioxide (CO₂) impurities. However, the BPHEs with only two channels cannot be applied directly in the conventional liquefaction processes which are designed for multi-stream heat exchangers. Therefore, the liquefaction processes using BPHEs are different from the conventional PFHE processes. In this paper, four different liquefaction processes using BPHEs are optimized and comprehensively compared under respective optimal conditions. The processes are compared with respect to energy consumption, economic performance, and robustness. The genetic algorithm (GA) is applied as the optimization method and the total revenue requirement (TRR) method is adopted in the economic analysis. The results show that the modified single mixed refrigerant (MSMR) process with part of the refrigerant flowing back to the compressor at low temperatures has the lowest specific energy consumption but the worst robustness of the four processes. The MSMR with fully utilization of cold capacity of the refrigerant shows a satisfying robustness and the best economic performance. The research in this paper is helpful for the application of BPHEs in natural gas liquefaction processes.     

Optimal thermal design of microchannel heat sinks with different geometric configurations

In this study, three-dimensional models of microchannel heat sinks (MCHSs) with different geometric configurations (such as single-layered- (SL), double-layered- (DL) or tapered-(T)-channels) are constructed by an optimization procedure. This procedure integrates a direct problem solver with a simplified conjugate-gradient method as the optimizer. The overall thermal resistance of an MCHS is the objective function to be minimized with respect to geometric parameters, such as the number of channels, channel width ratio, channel aspect ratio and tapered ratios, as the search variables. The optimal thermal resistance is found to decrease in the following order: the initial guess parallel channel (IGP channel), SL-, DL- and T-channel designs. In addition, the T-channel design has the minimum temperature difference and the most uniform temperature distribution, followed by the DL-, SL- and IGP-channel designs. Moreover, the optimal thermal resistance reduces with the pumping power for the various channel configuration designs, and the lowest thermal resistance corresponds to the T-channel design. The larger the pumping power, the larger the decrement in thermal resistance. Therefore, the optimal T-channel is the best MCHS design when considering thermal resistance and temperature distribution uniformity.     

Evaluation of storage configurations with internal heat exchangers

An international standard, ISO/DP 9459-4A, 1996 has been proposed to establish a uniform standard of quality for small solar heating systems. In this proposal, system components are tested separately and total system performance is calculated using system simulations based on validated component model parameter values. Another approach is to test the whole system in operation under representative conditions, where the results can be used as a measure of the general system performance. Component testing and system simulation is flexible, but requires an accurate and reliable simulation model. The advantage of system testing is that it is not dependent on simulations and that it shows the actual system performance. Its disadvantage is that it is restricted to the boundary conditions for the test.

The heat store is a key component concerning system performance. Thus, this work focuses on the storage system consisting of store, electrical auxiliary heater, internal heat exchangers (solar and load loops) and tempering valve. Four different storage system configurations with a volume of 750 l were tested in an indoor system test using a statistically generated six-day test sequence and a solar collector simulator. A store component test and system simulation was carried out on one of the four configurations, applying the proposed standard for stores, ISO/DP 9459-4A, 1996 and the MULTIPORT store model. Three test sequences for internal load side heat exchangers, not in the proposed ISO standard, were also carried out. This paper discusses the results of the indoor system test, the store component test, the validation of the store model parameter values and the system simulations.     

Numerical estimation of pressure drop and heat transfer characteristics in annular‐finned channel heat exchangers with different channel configurations

In this numerical investigation, three‐dimensional analysis has been used to study the effect of finned channels configuration of (circular, square, and triangular shape) and fin spacing with four rows in staggered arrangements. The finite volume method with k‐ ω turbulent model is applied to estimate the heat transfer and flow characteristics. The results illustrate that the development of the boundary layer between the fins surfaces is credited to the finned channels configuration, fin spacing, and Reynolds number. Moreover, the results of pressure drop and heat transfer with various channel configuration and different fin spacings (1.6, 2, and 4 mm) are presented and validated with the available correlations. The triangular‐finned channel with 1.6 mm fin spacing offered higher heat transfer enhancement followed by square‐ and circular‐finned channels. A considerable agreement was observed when the current findings and the existing correlations were compared, with a maximum deviation of 15% for all the cases.     

铝扁管内R410A冷凝传热特性研究

为了探究制冷剂在多孔铝扁管内的冷凝传热特性,采用实验方法对 R410A在多孔铝扁管内的冷凝传热和压降特性进行了研究。冷凝温度分别为47、40和30℃,单位截面质量流率在200~600kg/(m2·s)。给出了实验 测 试 结 果,并 采 用 公 开 发 表 的 学 术 文 献 中 的 模 型 与 这 些 实 验 测 试 结 果 进 行 了 对 比。 Müller-Steinhagen和 Heck模型预测压降的精度最高,它预测93.3%测试点的偏差在±20%之内,预测100%测试点的偏差在±30%之内。Koyama等模型预 测 传 热 系 数 的 精 度 最 高,它 预 测 93.3%测 试 点 的 偏 差 在 ±10%之内,预测100%测试点的偏差在±20%之内。     

Comparative study on evaporator heat transfer characteristics of revolving heat pipes filled with R134a, R22 and R410A

Heat pipes are used extensively in various applications including the heating, ventilating and air conditioning (HVAC) systems. The high thermal conductivity of the device, attributed from the two-phase heat transfer processes within the heat pipe, made them superior heat exchanger devices. Heat pipes had been widely used in HVAC applications in energy conservation, dehumidification enhancement, heat dissipation, etc. A number of researches have been conducted to expand the applicability of heat pipes in HVAC in Malaysia, especially in air-to-air heat recovery using stationary heat pipes. However, the potential usage of rotating heat pipe in heat recovery in tropical countries like Malaysia was yet to be explored. Hence, the potential of rotating heat pipe in the HVAC systems used in tropics was explored through a parametric study that incorporates rotational speeds, off-axis displacements and varied refrigerants. The rotating heat pipes charged with R134a, R22 and R410A were tested with varied radial displacement from the rotational axis. The straight and leveled heat pipe with the furthest radial displacement yields the most significant heat transfer, which was attributed to the magnitude of the generated centrifugal force, and effective distribution of liquid in the evaporator.     

Dimensional analysis on the evaporation and condensation of refrigerant R-134a in minichannel plate heat exchangers

Two-phase flow analysis for the evaporation and condensation of refrigerants within the minichannel plate heat exchangers is an area of ongoing research, as reported in the literatures reviewed in this article. The previous studies mostly correlated the two-phase heat transfer and pressure drop in these minichannel heat exchangers using theories and empirical correlations that had previously been established for two-phase flows in conventional macrochannels. However, the two-phase flow characteristics within micro/minichannels may be more sophisticated than conventional macrochannels, and the empirical correlations for one scale may not work for the other one. The objective of this study is to investigate the parameters that affect the two-phase heat transfer within the minichannel plate heat exchangers, and to utilize the dimensional analysis technique to develop appropriate correlations. For this purpose, thermo-hydrodynamic performance of three minichannel brazed-type plate heat exchangers was analyzed experimentally in this study. These heat exchangers were used as the evaporator and condenser of an automotive refrigeration system where the refrigerant R-134a flowed on one side and a 50% glycol–water mixture on the other side in a counter-flow configuration. The heat transfer coefficient for the single-phase flow of the glycol–water mixture was first obtained using a modified Wilson plot technique. The results from the single-phase flow analysis were then used in the two-phase flow analysis, and correlations for the refrigerant evaporation and condensation heat transfer were developed. Correlations for the single-phase and two-phase Fanning friction factors were also obtained based on a homogenous model. The results of this study showed that the two-phase theories and correlations that were established for conventional macrochannel heat exchangers may not hold for the minichannel heat exchangers used in this study.     

Dimensional analysis for the heat transfer characteristics in the corrugated channels of plate heat exchangers

Using the Buckingham Pi theorem, this study derives dimensionless correlations to characterize the heat transfer performance of the corrugated channel in a plate heat exchanger. The experimental data are substituted into these correlations to identify the flow characteristics and channel geometry parameters with the most significant influence on the heat transfer performance. Simplified correlations by omitting the factors with less influence are then obtained. The results show that Nu_x is affected primarily by Re, R/D_h, x/D_h, and β. Neglecting the minor effect of factors on Nu_x, it is shown that Nu_m is determined primarily by Re, R/D_h and β.     

Thermal performance analysis of plate heat exchanger with different configurations for the heat recovery system in buildings

Due to the scarcity of conventional energy sources, a lot of efforts need to be taken regarding energy conservation in the buildings, including heat recovery of air ventilation systems. The present paper focuses on new methods to improve the thermal performance of the heat recovery system by investigating the heat transfer characteristics and the flow development in a flat-plate heat exchanger (FPHE) using three different rib-grooved surfaces (trapezoidal, triangle and semi-circular), the numerical simulations were carried out for uniform wall heat flux equal to 290 W/m² for air as the working fluid, the Reynolds number varies from 500 to 2000 for three different channel heights. The numerical results indicated that, rib-grooved surfaces have a significant impact on heat transfer enhancement with an increase in the pressure drop through the channel. The effect of rib-grooved patterns on the heat transfer and the fluid flow is more significant in a narrow channel especially for trapezoidal and triangle corrugated surfaces, because they have sharp edges. Based on the present research, the FPHEs with the added rib-grooved surfaces are recommended to provide an efficient and compact heat recovery system. Moreover, it was found that by applying the new design, a considerable amount of energy and power could be saved.     

Investigation of heat transfer and pressure drop in plate heat exchangers having different surface profiles

It would be misleading to consider only cost aspect of the design of a heat exchanger. High maintenance costs increase total cost during the services life of heat exchanger. Therefore exergy analysis and energy saving are very important parameters in the heat exchanger design. In this study, the effects of surface geometries of three different type heat exchangers called as PHE_flat (Flat plate heat exchanger), PHE_corrugated (Corrugated plate heat exchanger) and PHE_asteriks (Asterisk plate heat exchanger) on heat transfer, friction factor and exergy loss were investigated experimentally. The experiments were carried out for a heat exchanger with single pass under condition of parallel and counter flow. In this study, experiments were conducted for laminar flow conditions. Reynolds number and Prandtl number were in the range of 50 ? Re ? 1000 and 3 ? Pr ? 7, respectively. Heat transfer, friction factor and exergy loss correlations were obtained according to the experimental results.     

Local effects of longitudinal heat conduction in plate heat exchangers

In a plate heat exchanger, heat transfer from the hot to the cold fluid is a multi-dimensional conjugate problem, in which longitudinal heat conduction (LHC) along the dividing walls often plays some role and can not be neglected. Large-scale, or end-to-end, LHC is always detrimental to the exchanger’s effectiveness. On the contrary, if significant non-uniformities exist in the distribution of either convective heat transfer coefficient, small-scale, or local, LHC may actually enhance the exchanger’s performance by improving the thermal coupling between high heat transfer spots located on the opposite sides of the dividing wall.     

Numerical simulation and experimental research on heat transfer and flow resistance characteristics of asymmetric plate heat exchangers

The asymmetric plate heat exchanger (APHE) has the possibility of achieving balanced pressure drops on both hot and cold sides for situations with unbalanced flow, which may in turn enhance the heat transfer. In this paper, the single-phase water flow and heat transfer of an APHE consisted of two types of plates are numerically (400≤Re≤12000) and experimentally (400≤Re≤ 3400) investigated. The numerical model is verified by the experimental results. Simulations are conducted to study the effects of N, an asymmetric index proposed to describe the geometry of APHEs. The correlations of the Nusselt number and friction factor in the APHEs are determined by taking N and working fluids into account. It is found that an optimal N exists where the pressure drops are balanced and the heat transfer area reaches the minimum. The comparison between heat transfer and flow characteristics of the APHEs and the conventional plate heat exchanger (CPHE) is made under various flow rate ratios of the hot side and the cold side and different allowable pressure drops. The situations under which APHE may perform better are identified based on a comprehensive index Nu/f^1/3.     

Air side heat transfer characteristics of plate finned tube heat exchangers with slit fin configuration under wet conditions

An experimental study was performed on compact finned tube heat exchangers under wet conditions. Eight different finned tube heat exchangers having slit fins with hydrophilic coatings were tested. The effects of tube diameter, the number of tube rows, and inlet air relative humidity on air side heat transfer and pressure drop characteristics were investigated. Air side heat transfer coefficients were calculated using the log mean enthalpy difference method. The effects of the number of tube rows and the tube diameter on the Colburn j-factor and the f-factor were larger compared with those of the inlet air relative humidity. The Colburn j-factor and the f-factor of the single-row heat exchanger were larger than those of two- or three-row heat exchangers. The j-factor for the 5.30 mm tube diameter was compared with those for 7.35 mm and 9.95 mm tube diameters at 46% RH and was found to be 33% and 55% larger, respectively.     

A fast modelling tool for plate heat exchangers based on depth-averaged equations

In this study, the depth-averaged flow and energy equations for plate heat exchangers are presented. The equations are derived by integrating the original 3D flow and energy equations over the height of the gap between the bottom and top plates. This approach reduces the equations from 3D to 2D but still takes into account the frictions on the surfaces and heat transfer through the plates. The depth-averaging reduces the elapsed time of CFD simulations from hours to minutes. Thus, it is very practicable modelling method in real time design work. 2D CFD simulations with depth-averaged equations are compared with full 3D models for five different corrugation angles and corrugation lengths. The simulation results show that the 2D model predicts with relatively good accuracy the profile of the pressure drop and the temperature change as a function of the corrugation angle and the function of the corrugation length. In order to get more extensive information about the significance of the different geometry parameters on the efficiency of the heat exchanger, we simulated 30 different geometries with the fast 2D model. The results suggest that the temperature change is not as sensitive for the geometrical modifications as the pressure drop.     

Absorption of organic fluid mixtures in plate heat exchangers

It is well known that the absorber is the key component in energy conversion systems that are based on absorption cycles. This paper describes an experimental investigation into the absorption process of organic fluid mixtures in an absorption system which has a spray and a plate heat exchanger. The absorber consists of an adiabatic mixing chamber with a spray, where the solution that is weak in refrigerant is sprayed into the refrigerant vapour. A two-phase mixture is formed and enters a plate heat exchanger, where the solution is cooled to complete the absorption process.We carried out experiments with different types of spray nozzles using the organic fluid mixtures methanol–tetraethyleneglycol dimethylether (TEGDME) and trifluoroethanol (TFE)–TEGDME. We analyse how the solution mass flow rate, absorber pressure and cooling water temperature affected the absorber performance and we discuss the results in terms of the absorber load, absorbed mass flux, degree of subcooling of the solution at the absorber outlet, solution film heat and mass transfer coefficients.The results indicate that the absorption system proposed is suitable for relatively low pressures. For water temperatures of 30 °C and absorber pressures between 2 and 6 kPa, the absorption rates for TFE–TEGDME were 1 to 2.5 g·s⁻¹·m⁻². The corresponding values for methanol–TEGDME with absorber pressures between 10 and 15 kPa were 0.4 to 1.2 g·s⁻¹·m⁻².     

Prediction of heat transfer coefficient on the fin inside one-tube plate finned-tube heat exchangers

The finite difference method in conjunction with the least-squares scheme and the experimental temperature data is proposed to predict the average heat transfer coefficient and the fin efficiency on the fin inside one-tube plate finned-tube heat exchangers for various air speeds and the temperature difference between the ambient temperature and the tube temperature. Previous works showed that the heat transfer coefficient on this rectangular fin is very non-uniform. Thus the whole plate fin is divided into several sub-fin regions in order to predict the average heat transfer coefficient and the fin efficiency on the fin from the knowledge of the fin temperature recordings at several selected measurement locations. The results show that the surface heat flux and the heat transfer coefficient on the upstream region of the fin can be markedly higher than those on the downstream region. The fin temperature distributions depart from the ideal isothermal situation and the fin temperature decreases more rapidly away from the circular center, when the frontal air speed increases. The average heat transfer coefficient on the fin increases with the air speed and the temperature difference between the ambient temperature and the tube temperature. This implies that the effect of the temperature difference between the tube temperature and the ambient temperature is not negligent.     

A three-dimensional inverse problem in imaging the local heat transfer coefficients for plate finned-tube heat exchangers

A three-dimensional inverse heat conduction problem in imaging the local heat transfer coefficients for plate finned-tube heat exchangers utilizing the steepest descent method and a general purpose commercial code CFX4.4 is applied successfully in the present study based on the simulated measured temperature distributions on fin surface by infrared thermography.It is assumed that no prior information is available on the functional form of the unknown local heat transfer coefficients in the present study. Thus, it can be classified as function estimation for the inverse calculations.Two different heat transfer coefficients for in-line tube arrangements with different measurement errors are to be estimated. Results show that the present algorithm can obtain the reliable estimated heat transfer coefficients.     

A new method for heat transfer and fluid flow performance simulation of plate heat exchangers

Successful numerical simulation on heat transfer and fluid flow performances of plate heat exchangers is vital. Their complex structures often make the numerical calculation quite difficult and time-consuming. Conclusions drawn by the present work are promising for greatly simplifying the simulation. Different types of plates consisting of different numbers of periods are analyzed and it is concluded that the Nusselt number remains constant for different periods of different plates under different inlet velocities. The central friction coefficients behave the same as Nusselt number. For the first and last periods, the respective friction coefficient also remains for different plates. A small plate fraction with four periods is enough for performance prediction of any-sized plates.