Numerical and experimental analysis of thermodynamic properties of plate heat exchangers at high Reynolds number based on different single-phase fluid structures

Weicheng Xuan, Zhuoye Wang, Changtian Xu, Zekun Jiang, Ruixin Ma, Chenyi Qian, Jiaxuan Wang, Binbin Yu, Dandong Wang, Junye Shi and Jiangping Chen

Energy, 2025, vol. 324, issue C

Abstract: The structural design of plate heat exchanger (PHE) is pivotal for overcoming the limitations of heat flux density. This study investigates the heat transfer mechanisms of single-phase and two-phase flows in different structures, revealing distinct heat transfer enhancement patterns. A numerical model of PHE was first established, in which the heat transfer area of the offset fin structure was approximately 1.5–2 times that of the dimple. Simulations of single-phase demonstrated that at Reynolds number (Re) between 2000 and 2500, the offset fin structure achieved Nusselt number (Nu) of 20, which was 1.4 times that of the dimple, with a comparable pressure drop of around 9 kPa. Subsequently, two PHEs were fabricated using brazing, and a performance test rig was constructed. Experimental results further validated the single-phase conclusions from the simulations. Moreover, for two-phase, Nu of the PHE with the offset fin structure reached 800 at Re above 5000, which was 1.2 times that of the dimple. The significant difference in heat transfer performance between single-phase and two-phase flows highlighted distinct enhancement mechanisms: the heat transfer area was the decisive factor for single-phase heat transfer performance, while the intense disruption of thermal boundary layer dominated the two-phase side. Finally, empirical correlations for heat transfer and pressure drop on both sides of the PHE were derived. Experimental data verified that over 95 % of the fitted Nu and f had errors of less than 20 %. Therefore, the findings on the key factors influencing PHE heat transfer provide significant engineering insights for breaking the heat flux limits in traditional PHE structural designs.

Keywords: Plate heat exchanger; Two-phase; Single-phase; Fin; Dimple; Correlations (search for similar items in EconPapers)
Date: 2025
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Persistent link: https://EconPapers.repec.org/RePEc:eee:energy:v:324:y:2025:i:c:s0360544225016779

DOI: 10.1016/j.energy.2025.136035

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