Fluid Flow Distribution and Heat Transfer in Plate-Fin Heat Exchangers

Single-phase and two-phase flow distribution in plate-fin heat exchangers and the influence of nonuniform fluid flow distribution on the thermal performance of such heat exchangers were experimentally investigated. The experimental results show that flow maldistribution can be a serious problem in plate-fin heat exchangers because of nonoptimized header configurations. The uneven distribution of two-phase flow in plate-fin heat exchangers is more pronounced than that of single-phase flow. It is shown that the uneven distributions result in a significant deterioration of the heat transfer performance. The relationship between the flow maldistribution characteristics and the resulting loss in heat exchanger effectiveness has been studied in this work. Certain improved header configurations with perforated plates were proposed in order to solve the maldistribution problem. It was found that the new header configurations could effectively improve the thermal performance of plate-fin heat exchangers. By changing the header configuration, the degree of flow and temperature nonuniformity in the plate-fin heat exchanger was reduced to 16.8% and 74.8%, respectively, under the main test condition.     

Experimental research on the effects of distributor configuration on flow distribution in plate‐fin heat exchangers

The effects of different distributor configurations on the flow distribution in plate‐fin heat exchangers were studied. It was found that an irrational distributor configuration would lead to the flow maldistribution and a different degree of non‐uniformity of the flow distribution in the transverse and longitudinal directions. The distributor configuration and Reynolds number are the main factors affecting the flow distribution. An improved distributor configuration with a fluid complementary cavity has been brought forward. The experimental results showed that the improved distributor configuration can effectively improve the performance of flow distribution in heat exchangers. The best performance of flow distribution was obtained at h/H = 0.2. The correlations between the flow maldistribution characteristic and the flow Reynolds number for different distributor configurations were deduced according to the experimental data. © 2004 Wiley Periodicals, Inc. Heat Trans Asian Res, 33(6): 402–410, 2004; Published online in Wiley InterScience ( www.interscience.wiley.com ). DOI 10.1002/htj.20023     

Experimental Investigation on Fluid Flow Maldistribution in Plate-Fin Heat Exchangers

The plate-fin heat exchanger is normally designed with the assumption that the fluid is uniformly divided among all the parallel passages. In practice, however, the design of the exchanger, the heat transfer process, the operation of the external system, etc., may create high flow maldistribution. The performance deterioration of plate-fin heat exchangers due to flow maldistribution may be serious. In this review, the flow distribution performance in a plate-fin heat exchanger has been experimentally studied and the distribution performance of different distributors' inlet angles has been measured. The combined effects of the inlet angle and mass flow rate on flow maldistribution have been studied. The study is useful in the optimum design of plate-fin heat exchangers.     

Improvements on Flow Distribution and Heat Transfer Performance of Plate-fin Heat Exchangers by Qusai-S Type Header Configuration

In order to reduce flow maldistribution and enhance the heat transfer performance, an improved quasi-S-type header configuration of plate-fin heat exchangers is proposed. Based on the analysis of the fluid flow distribution, the results indicate that the outlet velocity of the conventional header is uneven. However, the qusai-S-type header not only effectively reduces the geometric mutation, but also extends the hydraulic path, which guides fluid to the two sides and thereby reduces the maldistribution. The qusai-S-type header was designed on the basis of the cubic curve (denoted as configuration B), Bézier curve (configuration C), or two semi-circular segments uniting with one-line segment (configuration D). Compared with the conventional header (configuration A), the maldistribution parameters for configuration B, C, and D decrease by 75.2–93.9%, 80–94.8%, and 78.4–94.3%, respectively. Yet, the power consumptions of them increase by 26.3%, 22.3%, and 42.3%, respectively. Besides, the effectiveness of the conventional plate-fin heat exchanger declines about 15.1% due to improper header configuration, while the decrease of effectiveness can be controlled within 2.0% using the improved header configurations. Therefore, the improved header configurations can effectively enhance the flow uniformity and the heat exchanger effectiveness, but with a low power consumption penalty.     

Experimental investigation of header configuration improvement in plate–fin heat exchanger

Flow characteristics in the header of a plate–fin heat exchanger have been investigated by means of Particle Image Velocimetry (PIV). A series of velocity vector and streamline graphs of different cross-sections are obtained in the experiment. The experimental results indicate that performance of fluid maldistribution in a conventional header is very serious, while the improved header configuration with a punched baffle can effectively enhance the uniformity of flow distribution. The flow maldistribution parameter and the ratio of the maximum velocity to the minimum in a plate–fin heat exchanger decreases by installing the punched baffle. Further heat exchange experiments indicate that the temperature is distributed more uniformly in the improved heat exchanger core and the heat exchanger effectiveness can be effectively enhanced. The conclusion of this paper is of great significance in the optimum design of plate–fin heat exchanger.     

Experimental investigation of header configuration on flow maldistribution in plate-fin heat exchanger

In this paper, the concept of second header installation is put forward. The experimental investigation on the effects of the inlet pipe diameter (Φ_1(in)), the first header’s diameter of equivalent area (Φ_1(out)) and the second header’s diameter of equivalent area (Φ_2(in) and Φ_2(out)) on the flow maldistribution in plate-fin heat exchanger (PFHE) is performed. The results indicate that the flow distribution in PFHE becomes more uniform when Φ_1(out)/Φ_1(in) is equal to Φ_2(out)/Φ_2(in). The correlation of the dimensionless flow maldistribution parameter S and Reynolds number is obtained under different header configurations. The ratio of the maximum flow velocity and the minimum flow velocity drops from 2.08–2.81 to 1.2–1.4 for various Reynolds numbers. The experimental studies prove that the performance of flow distribution in PFHE is effectively improved by the optimum design of the header configuration.     

An experimental and numerical investigation of flow patterns in the entrance of plate-fin heat exchanger

The turbulent flow structure inside the entrance of plate-fin heat exchanger was characterized by CFD simulation and PIV experiment under the similar conditions. A series of velocity vectors and streamline graphs of different cross-sections are achieved for three distinct header configurations, involving conventional and improved configurations. The numerical and experimental results indicate that the performance of fluid maldistribution in conventional entrance is deteriorated, while the improved configuration with punched baffle can effectively improve the performance in both radial and axial direction. And the baffle on which the small holes are distributed in staggered arrangement is the first choice for the improvement. CFD results and PIV data are in good agreement with each other. The results validate that PIV and CFD are well suitable to investigate complex flow patterns and the conclusion of this paper is of great significance in the optimum design of plate-fin heat exchanger.     

Numerical study of flow patterns of compact plate-fin heat exchangers and generation of design data for offset and wavy fins

Thermo-hydraulic design of compact heat exchangers (CHEs) is strongly dependent upon the predicted/measured dimensionless performance (Colburn factor j and Fanning friction factor f vs. Reynolds number Re) of heat transfer surfaces. Also, air (gas) flow maldistribution in the headers, caused by the orientation of inlet and outlet nozzles in the heat exchanger, affects the exchanger performance. Three typical compact plate-fin heat exchangers have been analyzed using Fluent software for quantification of flow maldistribution effects with ideal and real cases. The headers have modified by providing suitable baffle plates for improvement in flow distribution. Three offset strip fin and 16 wavy fin geometries used in the compact plate-fin heat exchangers have also been analyzed numerically. The j and f vs. Re design data are generated using CFD analysis only for turbulent flow region. For the validation of the numerical analysis conducted in the present study, a rectangular fin geometry having same dimensions as that of the wavy fin has been analyzed. The results of the wavy fin have been compared with the analytical results of a rectangular fin and found good agreement. Similarly, the numerical results of offset strip fin are compared with the correlations available in the open literature and found good agreement with most of the earlier findings.     

Thermal Compensation Effect of Passage Arrangement Design for Inlet Flow Maldistribution in Multiple-Stream Plate-Fin Heat Exchanger

ABSTRACT

Passage arrangement design in fin channels is an efficient methodology for the reduction of the thermal deterioration influence of inlet flow maldistribution in multiple-stream plate-fin heat exchangers. In this work, the thermal compensation effects of passage arrangement design under different statistical parameters of inlet flow maldistribution are investigated. The inlet flow maldistribution in inlet header is analyzed and represented with distribution types, mean, and standard deviation of inlet mass flow rate entering the fin channels. A thermal calculation model based on integer–mean temperature difference method is established, and then, the passage arrangement under inlet flow maldistribution is optimized using a hybrid particle swarm algorithm. The thermal compensation effects for different inlet flow maldistributions and passage arrangements are calculated and compared. The results indicate that the compensation effect of optimization design of passage arrangement increases from 1.1% to 3.9% as the standard deviation of inlet mass flow rate increases from 0.06 kg/s to 0.12 kg/s. The results presented in this study can be used by other researchers to guide the passage arrangement design of actual heat exchanger with inlet flow maldistribution.     

导流片结构对物流分配性能影响的实验研究

通过板翅式换热器物流分配问题的实验研究发现,不合理的导流片结构造成板翅式换热器内部物流分配极不均匀,以及在横向与纵向上物流分配不均匀的程度也不相同。同时提出了具有补液腔的新型导流片结构,并定义了新型导流片的结构参数。实验结果表明,采用新型的导流片可以有效的改进换热器内部物流分配不均匀的问题,同时还发现在实验的条件下结构参数为0．2的导流片具有最佳的导流性能,通过实验研究得到了不同导流片结构的物流分配不均匀特性与流体雷诺数之间的关系式。     

Expanded Microchannel Heat Exchanger: Nondestructive Evaluation

Abstract

Recent theoretical developments in expanded microchannel polymer-based heat exchangers were promising, but the initial experiments underperformed simple theory. In order to understand this discrepancy, this article introduces a nondestructive methodology for characterizing polymer heat exchangers. A computerized tomography (X-ray) scan was performed to diagnose the problem. The method was tested on the expanded microchannel polymer heat exchanger to determine the variations in geometry between the theoretical and experimental heat exchanger. Channels were found to have variable heights causing flow maldistribution. The results are discussed to guide further technological development of this approach to heat exchanger design and fabrication and lays the groundwork for an advanced discretized modeling.     

Flow maldistribution and thermal performance deterioration in a cross-flow air to air heat exchanger with plate-fin cores

The inlet and outlet duct geometry in an air to air compact heat exchanger is always irregular. A skewed Z-type arrangement is popular between the impinging flow and the core. Such duct placements usually lead to a non-uniform flow distribution on core surface. In this research, the flow maldistribution and thermal performance deterioration in cross-flow air to air heat exchangers are investigated. The inlet duct, the core and the outlet duct are combined together to calculate the flow distribution on core inlet face. First, a CFD code is used to calculate the flow distribution, by treating the plate-fin core as a porous media. Then a heat transfer model between the two air flows in the plate-fin channels is set up. Using the flow distribution data predicted, the heat exchange effectiveness and the thermal performance deterioration factor are calculated with finite difference scheme. Experiments are performed to validate the flow distribution and heat transfer model. The results indicate that when the channel pitch is below 2.0 mm, the flow distribution is quite homogeneous and the thermal deterioration due to flow maldistribution can be neglected. However, when the channel pitch is larger than 2 mm, the maldistribution is quite large and a 10–20% thermal deterioration factor could be found. The study proves that the inlet duct, the outlet duct, and the core should be coupled together to clarify flow maldistribution problems.     

Transient response of plate heat exchangers considering effect of flow maldistribution

Plate heat exchangers have been playing important role in the power and process industries in the recent past. Hence, it is important to develop simulation strategies for plate heat exchangers accurately. This analysis represents the dynamic behaviour of the single pass plate heat exchangers, considering flow maldistribution from port to channel. In addition to maldistribution the fluid axial dispersion is used to characterise the back mixing and other deviations from plug flow. Due to unequal distribution of the fluid, the velocity of the fluid varies from channel to channel and hence the heat transfer coefficient variation is also taken into consideration. Solutions to the governing equations have been obtained using the method of Laplace transform followed by numerical inversion from frequency domain. The results are presented on the effects of flow maldistribution and conventional heat exchanger parameters on the temperature transients of both U-type and Z-type configurations. It is found that the effect of flow maldistribution is significant and it deteriorates the thermal performance as well as the characteristic features of the dynamic response of the heat exchanger. In contrast to the previous studies, here the axial dispersion describes the inchannel back mixing alone, not maldistribution, which is physically more appropriate. Present method is an efficient and consistent way of describing maldistribution and back mixing effects on the transient response of plate heat exchangers using an analytical method without performing intensive computation by complete numerical simulation.     

The combined effects of longitudinal heat conduction,flow nonuniformity and temperature nonuniformity in crossflow plate-fin heat exchangers

An analysis of a crossflow plate-fin compact heat exchanger, accounting for the combined effects of two-dimensional longitudinal heat conduction through the exchanger wall and nonuniform inlet fluid flow and temperature distribution is carried out using a finite element method. A mathematical equation is developed to generate different types of fluid flow/temperature maldistribution models considering the possible deviations in fluid flow. Using these models, the exchanger effectiveness and its deterioration due to the combined effects of longitudinal heat conduction, flow nonuniformity and temperature nonuniformity are calculated for various design and operating conditions of the exchanger. It was found that the performance variations are quite significant in some typical applications.     

Interpreting and Applying Experimental Data for Plate-Fin Surfaces: Problems with Power Law Correlation

The absence of reliable and theoretically consistent correlations for the prediction of the thermohydraulic performance of plate-fin surfaces from the definition of surface structure is placing a constraint upon plate-fin exchanger design. Many workers have made direct use of the experimental data without fully appreciating the limitations imposed by the way in which the experiments have been conducted. The dangers of such a practice are exposed. The data of Kays and London are then re-analyzed using established heat transfer theory. The comparison between the predicted and reported friction factor and j factor data is good. The predictions compare favorably with experimental measurements over laminar, transitional, and turbulent flow regimes. Predictions for heat transfer in the transitional flow regime can be improved if the transition occurs at a lower Reynolds number. The new equations can be used in design with greater confidence than the use of experimental data alone.     

Numerical model of a thermoelectric generator with compact plate-fin heat exchanger for high temperature PEM fuel cell exhaust heat recovery

This paper presents a numerical model of an exhaust heat recovery system for a high temperature polymer electrolyte membrane fuel cell (HTPEMFC) stack. The system is designed as thermoelectric generators (TEGs) sandwiched in the walls of a compact plate-fin heat exchanger. Its model is based on a finite-element approach. On each discretized segment, fluid properties, heat transfer process and TEG performance are locally calculated for higher model precision. To benefit both the system design and fabrication, the way to model TEG modules is herein reconsidered; a database of commercialized compact plate-fin heat exchangers is adopted. Then the model is validated against experimental data and the main variables are identified by means of a sensitivity analysis. Finally, the system configuration is optimized for recovering heat from the exhaust gas. The results exhibit the crucial importance of the model accuracy and the optimization on system configuration. Future studies will concentrate on heat exchanger structures.     

Studies on pumping power in terms of pressure drop and heat transfer characteristics of compact plate-fin heat exchangers—A review

Renewable energy sources like solar energy, wind energy, etc. are profusely available without any limitation. Heat exchanger is a device to transfer the energy from one fluid to other fluid for many applications in buildings, industries and automotives. The optimum design of heat exchanger for minimum pumping power (i.e., minimum pressure drop) and efficient heat transfer is a great challenge in terms of energy savings point of view. This review focuses on the research and developments of compact offset and wavy plate-fin heat exchangers. The review is summarized under three major sections. They are offset fin characteristics, wavy fin characteristics and non-uniformity of the inlet fluid flow. The various research aspects relating to internal single phase flow studied in offset and wavy fins by the researchers are compared and summarized. Further, the works done on the non-uniformity of this fluid flow at the inlet of the compact heat exchangers are addressed and the methods available to minimize these effects are compared.     

Experimental Determination of the Heat Transfer Coefficient of a Plate-Fin Heat Exchanger

Heat transfer in compact plate-fin heat exchangers is augmented by the introduction of complex fin patterns in the channels. Kays and London presented a lot of experimental data for several types of fin configurations, and many authors followed their example with other types of fins. For some fin types, the heat transfer correlation for the Nusselt number cannot be found in literature. Most of the data are given for large scale model fins in good controlled laboratory environments—little data is available for real heat exchangers.

A test rig was constructed at Ghent University to verify the performance of several fin types. Measurements were done on a real heat exchanger and not on a large scale model in order to determine the performance under real operational conditions.

The measurement setup consists of a hot water circuit and an air circuit with a fan. In the heat exchanger, 40 thermocouples are introduced on the air side and the wall. This way, the convection coefficient of the fins can be determined for a broad range of Reynolds numbers.

In the paper the measurement set-up is discussed and the measurements are presented. An in depth error analysis is performed on the measurements. This way a heat transfer correlation is provided with a tight error margin for compact plate-fin air coolers.     

Effect of Flow Distribution to the Channels on the Thermal Performance of the Multipass Plate Heat Exchangers

Over last two decades, plate heat exchangers (PHEs) have presented themselves as a viable alternative to the conventional shell and tube heat exchangers in the process and power industries. The thermal theory available for plate heat exchangers in the literature largely works on the assumption of equal flow in each channel. However, it is well known that the distribution of fluid from port to channel in PHE is far from being uniform. The present study brings about this port to channel flow distribution effect on the thermal behavior of multipass plate heat exchangers. The variation of the heat transfer coefficient due to flow variation from channel to channel has also been taken into consideration. Heat exchangers with both equal and unequal passes of the fluids have been studied. The results indicate that the flow maldistribution severely affects the performance of plate heat exchangers, and multipassing can act as an important tool to reduce the deterioration in performance due to maldistribution. The results show that with a low number of passes, the increase of velocity of fluid may be counterproductive in terms of heat transfer enhancement. Also, adding plates in order to increase the heat transfer surface may not be effective due to an increase in flow maldistribution. The correlations for 1-1, 1-2, 2-2, and 2-3 pass plate heat exchangers with the maldistribution index as a parameter are also presented.     

Experimental Investigation on Port-to-Channel Flow Maldistribution in Plate Heat Exchangers

Experiments have been conducted to analyze the flow and pressure distribution in a plate heat exchanger by measuring local port pressure distribution in a commercial plate heat exchanger. Flow rate in channel and channel pressure drops are evaluated by measuring the pressure inside the inlet and exit ports at different locations for different port dimensions. In these experiments, the measurement of pressure is done without disturbing the fluid flow inside the port. This technique also offers the option of manipulating port size without changing the plate characteristics. Direct experimental measurement provides the scope for eliminating other effects, such as gasket, end losses, and improper wetting of channels from the flow maldistribution effect. The measurements indicate the existence of non-uniform flow distribution that increases with flow rate and decreases with port diameter. Results clearly show that it is important to consider the flow maldistribution for better design of plate heat exchangers.