Design and analysis of plate heat exchanger with co2 and r134a as working f

International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 –
6340(Print), ISSN 0976 – 6359(Online) Volume 4, Issue 4, July - August (2013) © IAEME
311
DESIGN AND ANALYSIS OF PLATE HEAT EXCHANGER WITH CO2 AND
R134a AS WORKING FLUIDS
T K S Sai Krishna, S G Rajasekhar, C Pravarakhya.
IV Year B. Tech Mechanical, SMBS, VIT UNIVERSITY, Vellore.
ABSTRACT
The purpose of this study is to design a optimal plate type heat exchanger for refrigeration
systems. For many industrial applications plate heat exchangers are demonstrating a large superiority
over the other types of heat exchangers. In this paper we present both theoretical and simulation
analysis for a parallel flow heat exchanger. In this paper we performed analysis using two different
working fluids which are i.e., CO2 and R134a used only for refrigeration systems. We got the results
regarding heat transfer and also observed a very low pressure drop. By knowing the inlet conditions
like mass flow rate, temperature, pressure of both hot and cold fluid streams, we performed CFD
analysis in ANSYS software. The optimal design of multi-pass plate type heat exchanger is designed
by optimizing the variables such as number of passes for both streams, no. of plates, plate type and
size. In this paper we formulated the equations of heat transfer, pressure drop, overall heat transfer
coefficient etc. The selection of suitable material is taken based on thermal aging of materials,
stresses induced at high temperatures, failure or fatigue mode from the previous works. After
obtaining all these values the model is simulated in ANSYS, where we obtained better and accurate
results compared to theoretical analysis.
Key Words: ANSYS, CFD, simulation, PHE, Meshing, Nusselt number, Prandtl number.
INTRODUCTION
In many applications like air conditioning, refrigeration, heat recovery industries like thermal,
nuclear power industries, heat exchangers are used to transfer energy from one fluid to another
mostly used heat exchangers are boilers, condensers, economizers etc. in thermal and nuclear power
industries. Car radiators are also heat exchangers which transfer heat from IC engine to air or water.
For efficient heat recovery mostly compact type heat exchangers are used one of them has high heat
transfer coefficient which is known as plate type heat exchanger. It is used in many industries
because of its efficient heat recovery, light weight, compact design, easy to maintain, less floor space
than compared to other heat exchangers. Minimal maintenance, cost effectiveness and especially
high efficiency are the main factors to select plate type heat exchanger. To develop a heat exchanger
INTERNATIONAL JOURNAL OF MECHANICAL ENGINEERING
AND TECHNOLOGY (IJMET)
ISSN 0976 – 6340 (Print)
ISSN 0976 – 6359 (Online)
Volume 4, Issue 4, July - August (2013), pp. 311-318
© IAEME: www.iaeme.com/ijmet.asp
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312
in this field is a big challenge to many researchers and authors in terms of efficiency and economic
considerations [2,3,4]. Many studies were carried out on multichannel PHE’s by authors and
presented it in a simple thermal model. The thermal and hydraulic performance of PHE with certain
size and type of corrugations can be varied with two ways by adjusting number of passes and proper
selection of corrugation pattern. The optimal design of PHE by adjusting corrugation pattern was
done by Wang and sunden. Regarding the material selection YorikataMizokami, ToshihideIgari et al
[5] done analysis on materials that effect due to thermal aging, stresses and temperatures, which
obtained best results. The mathematical modelling of PHE was done by H. Dardour, S. Mazouz et al
[6]. The properties of CO2 and R134a are obtained from HMT data book by C.P.Kothandaraman [7].
The main approach of this paper is done through by calculating temperatures at each channels by
fixing the both inlet conditions of hot and cold fluid streams, calculated theoretically and compared
to simulated results which obtained similar values. Increasing or decreasing the number of plates has
been done according to the expected simulation results.
PLATE HEAT EXCHANGER DESCRIPTION
Plate heat exchanger consists of stack of metal plates which are made up certain material and
gap between successive plates is the channels for liquid to flow along the plates. Plate separates both
hot and cold fluids which allows heat transfer to be carried out. The first and last plates have fluid
only on one side. The heat transfer is carried out in parallel flow process through the channels where
cold fluid becomes warmer and hot fluid becomes cooler.
Fig 1.Simplified Schematic model of PHE in Parallel flow arrangement
HEAT EXCHANGER BASIC FORMULATION
For prediction of performance of PHE, when inlet and outlet conditions and overall heat
transfer coefficients are known it is better to use NTU- effectiveness method.
NTU = UA/Cmin
Where Cmin is the minimum value of (m*cp), A= (no.of plates × area per plate), U is the
overall heat transfer coefficient. The dimensionless effectiveness of PHE is defined as ratio of actual
heat transfer to the maximum heat transfer.
Ɛ = Cc (Tc out –Tc in)
Cmin(Th in - Tc in)
Where hin and Cin denotes hot and cold fluid inlet data.

313
SOLIDWORKS MODELLING
To analyse the temperature variations in the plate type heat exchanger model is modelled in
SOLIDWORKS according to the new design and the required length, width, height, No .of plates,
and thickness of the plates. The exploded view of different parts concerning the heat exchanger are
shown in the figure.
Explode View of the Plate Type Heat Exchanger
COMPUTATIONAL MODEL
To analyse the temperature variations in the heat exchanger a computational model of only
the fluid part is modelled with required no of plates and the part is modelled only of the fluid path
inside the plate and the directional losses are neglected in the analysis.
Fig 3. Ansys modelling Fig 4. Meshing of single plate in Ansys

314
GRID USED: Tetrahedron(Grid Independence is achieved)
No of Grids : 36782 No of Nodes : 44546
MATHEMATICAL MODELLING
Hypothesis
A set of assumptions must be introduced to develop a mathematical model of PHE.
The set of assumptions are
• The plate heat exchanger operates under steady state conditions.
• No phase change occurs: both fluids are single phase and are unmixed.
• Heat losses are negligible
• The temperature in the fluid streams is uniform over the flow cross section.
• There is no thermal energy source or sink in the heat exchanger.
• The fluids have constant specific heats.
• The fouling resistance is negligible.
Problem formulation and Governing equations
In PHE the two fluids exchange heat energy through the separating plates.
Applying steady flow energy conservation equation between the two plates gives:
For the first channel:
Change in H + q2 = 0
where q2 is the heat flux per unit length, H is the enthalpy of the fluid.
q2 = UA(T2 – T1)
where U is the overall heat transfer coefficient, A is the surface area of the plate. Similar equations
are also established for the others channels.
Hot side Cold side
Mass flow rate [kg/s] 0.2 0.2
Inlet temperatures [K] 288 273
Plate length[m] 1
Plate width[m] 0.3
Plate thickness[m] 0.002
Distance between the plates[m] 0.01
Plate material Aluminium
Gasket material NBR
OPERATING CONDITIONS
Heat exchanger data

315
Using the above boundary conditions the temperatures in different channels at different lengths are
calculated.
In this paper CO2 and R134a are used as working fluids.
HEAT TRANSFER COEFFICIENT CALCULATIONS
Reynolds number Re = (4*m)/(µ*p)
m-mass flow rate of refrigerant=0.2 kg/s
p- perimeter of plate=0.62
By substituting the values in the Reynolds number equation
Re = (4*0.2)/(1.08×10-5
×0.62)
Re = 119474.313
Substitute the Re in the nusselt number equation.
Nusselt number Nu =0.023*Red
0.8
*prn
Pr = (µ×cp)/k = 0.7215
n = 0.4 for heating
n = 0.3 for cooling
By substituting the Reynolds and prandtl number Nusselt number derived
Nu = 240.44
h1 =195.01275 w/m2
k.
Using the same procedure the heat transfer coefficient is found
For CO2 at 273k and 1atm
Re = (4*m)/(µ*p)
m-mass flow rate of coolant=0.2 kg/s
p- perimeter of plate=0.62
Re = (4*0.2)/(1.657×10-5
×0.62)
Re = 77871
Nusseltnumber Nu = 0.023*Red
n
*pr0.4
Pr=0.74
Nu = 166.925
h2 = 233.89 w/m2
k.
For calculating overall heat transfer coefficient U
1
U =
(1/h1)-(1/h2)
By substituting the values of h1 and h2 U = 90 w/m2
k.
From these calculations NTU and Effectiveness is found to be 3.4 and 0.42.
Using the h1 and h2 as input values for the simulation the temperature variations are obtained
from one plate to another from the top to bottom. Temperature variations of the body to body
interface is neglected as we are mainly concern of the inlet and outlet temperatures of the fluids
passing.

316
RESULTS AND DISCUSSIONS
The physical properties of the fluids used are
PROPERTIES OF THE FLUID CO2 AT 0 Degrees R134 a AT 15
Degrees
THERMAL
CONDUCTIVITY(w/mk)
0.013512 0.02326
SPECIFIC HEAT
CAPACITY(J/Kg.K)
816 901
DYNAMIC
VISCOSITY(Ns/m3
)
16.57×10-6
1.802×10-5
CONVERGENCE CRITERIA
GRID INDEPENDENCE is achieved in all the simulations
Contours Obtained for the Last plate are:
Fig Temperature contour on top surface Fig .Pressure contour of first channel

317
• From the above figure it is observed that Hot fluid temperature is decreased and cold fluid
temperature is increased.
• From the above figure it is observed that there is a slightly pressure drop at the entry of the
inlet of plate remaining area it is very low.
Fig. TEMPERATURE VARIATIONS OF THE FLUIDS THROUGHOUT THE LENGTH OF THE
HEAT EXCHANGER
To achieve very slight variations in the inlet and outlet temperatures of the both the fluids
mainly to cool the R134a we used eight plates in this design and it is observed that the temperature
changes are very high in the starting plates and goes on decreasing to the ending plates of the heat
exchanger as the temperature differences decreases.
CONCLUSION
The plate type heat exchanger is modelled in solid works and the fluid flow analysis is done
on the modelled fluid part. The analysis stated that when the thickness of the plates decreases then
the heat flow is higher and if the number of plates increases then the outlet temperature difference of
the fluids increased and the pressure contour stated that, there is little pressure drop in the entry and
outlet of the fluid, From the turbulent contour it is interfered that there is very high turbulence in the
entry and outlets due to sudden change in cross section along the plates. In future analysis, the heat
exchanger will be modelled and the temperature difference will be optimised by variations in the
design. We will try to employ this PHE as intercooler (which is the main aim) in multistage
refrigeration system which attains low work input, better C.O.P, and efficiency.

318
REFERENCES
[1]. Optimal design of plate-and-frame heat exchangers for efficient heat recovery in process
industries. Olga P. Arsenyeva b, et al(2011),pp. 4588-4598.
[2]. J. A. W. Gut, J. M. Pinto, Modelling of plate heat exchangers with generalized configurations,
International journal of heat and mass transfer,, 2003, pp. 2571-2585.
[3]. R. K. Shah, W. W. Focke, Plate heat exchangers and their design theory, Heat transfer
Equipment Design, Hemisphere, New York, 1988,pp. 227-254.
[4]. T. Zaleski, K. Klepack Approximate method of solving equations for plate heat exchangers,
International journal of heat and mass transfer, vol. 35, n°5 , pp. 1125-1130.
[5]. Numerical Analysis of Plate Heat Exchanger Performance in Co-Current Fluid Flow
Configuration. H. Dardour, S. Mazouz, and A. Bellagi (2009).
[6]. Development of structural design procedure of plate-fin heat exchanger for HTGR.
YorikataMizokamia,ToshihideIgari b, FumikoKawashimae, et al.(2011),pp. 248– 262.
[7]. HMT Data book by C.P.Kothandaraman(2012).
[8]. Sunil Jamra, Pravin Kumar Singh and Pankaj Dubey, “Experimental Analysis of Heat Transfer
Enhancement in Circular Double Tube Heat Exchanger using Inserts”, International Journal of
Mechanical Engineering & Technology (IJMET), Volume 3, Issue 3, 2012, pp. 306 - 314,
ISSN Print: 0976 – 6340, ISSN Online: 0976 – 6359.
[9]. Prof.Alpesh V Mehta, Nimit M Patel, Dinesh K Tantia and Nilsh M Jha, “Mini Heat Exchanger
Using Al2o3-Water Based Nano Fluid”, International Journal of Mechanical Engineering &
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Online: 0976 – 6359.

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