Experimental Thermal and Fluid Science 30 (2006) 811819

www.elsevier.com/locate/etfs

New printed circuit heat exchanger with S-shaped ns

for hot water supplier
Tri Lam Ngo *, Yasuyoshi Kato, Konstantin Nikitin, Nobuyoshi Tsuzuki
Research Laboratory for Nuclear Reactors, Tokyo Institute of Technology, 2-12-1 O-okayama, Meguro-ku, Tokyo 152-8550, Japan

Abstract
A new PCHE with an S-shaped n conguration was applied to a hot water supplier in which cold water of 7 C is warmed to 90 C
through heat-exchange with supercritical CO2 of 118 C and 11.5 MPa pressure. The n and plate congurations were determined using
3D CFD simulations for the CO2 side and H2O side and the thermalhydraulic performance of hot water supplier was evaluated. Compared with a hot water supplier that is currently used in a residential heat pump, the new PCHE provides about 3.3 times less volume;
and lower pressure drop by 37% in the CO2 side and by 10 times in H2O side.
 2006 Elsevier Inc. All rights reserved.
Keywords: Printed circuit heat exchanger; Supercritical CO2; Hot water supplier; Waste heat recovery; Overall heat transfer coecient; Pressure drop

1. Introduction
Compactness and eciency improvement of heat
exchangers are important, particularly for cost reduction,
in all energy system: modern air-conditioning, heat pumps,
refrigeration, and waste heat recovery systems for variety
of residential, industrial, automotive and process industry
applications. A Printed Circuit Heat Exchanger (PCHE)
is a promising candidate for compact heat exchangers.
Two technologies are applied to manufacture the PCHE:
photo-etching and diusion bonding.
Compactness of the heat exchangers is usually expressed
by using the Colburn j factor, given as
Dh 2=3
j
Pr N ;
1
4L
where N = NTU (number of thermal units), and
N T o  T i =DT LMTD :

Reduction of the hydraulic diameter engenders a decreased

active length L or heat exchanger size at the same Colburn j
*

Corresponding author. Tel.: +81 3 5734 3293; fax: +81 3 5734 2959.
E-mail addresses: 04d51446@nr.titech.ac.jp (T.L. Ngo), kato@nr.titech.ac.jp (Y. Kato).
0894-1777/$ - see front matter  2006 Elsevier Inc. All rights reserved.
doi:10.1016/j.expthermusci.2006.03.010

factor, Pr and N conditions, as shown in Eqs. (1) and (2)

(Hesselgreaves, 2001). The hydraulic diameter is easily
reducible in PCHEs because photo-etching technology can
mill small ow channels. Such reductions are not achieved
easily in usual plate n exchangers because plate n manufacturing and brazing bonding costs increase with increase
of n density or reduced hydraulic diameter. For PCHE,
hydraulic diameter reduction is not limited by the manufacturing cost increment, but by the pressure drop increment,
which is roughly inversely proportional to the channel
diameter. Although the pressure drop is not a constraint
for application to high system-pressure plants, it will be
the main barrier to the use of such heat exchangers. A previous study introduced a new PCHE with the S-shaped ns
[1]. It reduces the pressure drop while retaining high heattransfer performance, thereby extending the PCHE application eld to lower-pressure plants.
The diusion bonding technology maintains the parent
material strength because of no ux, braze or ller exist
in the heat exchanger core. This provides high capability
of corrosion and temperature resistance.
The new PCHE was proposed for a recuperator of a carbon dioxide (CO2) gas turbine cycle in the previous study
that eliminates the drawback of high pressure drop in a

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T.L. Ngo et al. / Experimental Thermal and Fluid Science 30 (2006) 811819

Nomenclature
A
cp
Dh
df
dy  df
f
h
j
J
k
L
Lx, Ly,
lx
M
N
Nu
n
P
Pr
Q

surface area of heat exchanger, m2

specic heat, J/kg K
hydraulic diameter, mm
n width, mm
ns gap, mm
friction factor
local HTC, W/m2 K
Colburn factor
number of banking congurations
thermal conductivity, W/m K
active heat exchanger length, mm
Lz dimension in x, y, z directions
n length in the x-direction, mm
number of simulation parts
number of thermal units
Nusselt number
number of uid ow channels
pressure, MPa
Prandtl number
heat load, W

conventional PCHE with zigzag ows [2,3] keeping the

advantage of high heat transfer performance. The purpose
of this study is to expand applicability of the new PCHE
from the gas (CO2)-gas (CO2) heat exchanger of the recuperator for the CO2 gas turbine cycle system to a gas
(CO2)-liquid (H2O) heat exchanger or a hot water supplier
for a residential use [4].

T
t
U
V
W

temperature, C
wall thickness, mm
overall HTC, W/m2 K
volume, m3
ow rate, kg/h

Greek symbols
h
n angle
D
denotes dierence
r
stress, MPa
Subscripts and superscripts
CFD computer uid dynamics
c, h
cold, hot uid, respectively
i, o
inlet, outlet, respectively
LMTD log-mean temperature dierence
m
Number of simulation parts
w
wall
tot
total

Sine curve
dy
df
lx

2. Analytical method

2.1. Flow channel conguration with S-shaped ns

The ow channel conguration is shown in Fig. 1. The
ns with an S-shape are made from a sine curve. The n
angle h is slope of the tangential line at the center of the
n measured from the horizontal line, as shown in Fig. 2.
Points A and B are the peaks and trough of a sine curve
and the distance from A to B is dened as the n length;

Fig. 2. Fin shaped in the models.

n width is df, and the n gap is determined as (dy  df).

The same pattern is repeated as illustrated in Fig. 1. The
S-shaped ns are used for both sides of hot and cold
channels.
2.2. Plate conguration model

Fig. 1. Flow channel conguration.

Typical plate congurations used for three-dimensional

computational uid dynamic (3D-CFD) simulations are
illustrated in Fig. 3 for a single-banking and a doublebanking model. A cold plate and a hot plate are stacked
alternatively, so-called single-banking. One cold plate and

T.L. Ngo et al. / Experimental Thermal and Fluid Science 30 (2006) 811819

813

120

(a) Single banking

Cold flow
inlet

Lx
Lz

Flow direction

Fig. 3. Simulation models

z
y
x

Ly

Lx

CO2; 11.5 MPa

100

Temperature, T(oC)

Hot flow
inlet

H2O; 0.25 MPa

80
o

5C
60
40
20

(b) Double banking

Fig. 3. Simulation models.

two hot plates are stacked in a sandwich structure, socalled double-baking.

The typical dimension of simulation model is Lx
Ly Lz = 136.17 18.56 7.26 mm, which varies among
models. The hot and cold uids enter the model from x
and +x-axis directions. They exit respectively the +x and
x directions. The periodic boundary condition is applied
for outer surfaces of the front, back, top, and bottom sides
in the single-banking model. It is applied for outer surfaces
of front and back sides in double-banking model, and other
sides, top and bottom surfaces, are applied adiabatic
boundary conditions.

0
0
CO2 Inlet

1000

H2O Outlet

2000

3000

4000

Heat load, Q (W)

5000
CO2 Outlet

H2O Inlet

Fig. 4. Working uid temperature as a function of heat load.

Table 1
Simulation conditions

Ti (C)
To (C)
P (MPa)
W (kg/h)
Q (kW)
Plate material

CO2 side

H2O side

118
16
11.5
57.8

7
90
0.25
48.0
4.6
Copper

2.3. Three-dimensional CFD simulation

Simulation calculations were carried out using the 3DCFD code, FLUENT [5]. The governing equations are considered for continuity, momentum and energy equations.
Turbulence is taken into account by the ReNormalization
Group (RNG) ke model and enhanced wall treatment.
All equations are solved by second-order upwind discretization for convection. The Semi Implicit Method Pressure
Linked Equation (SIMPLE) algorithm is used to resolve
coupling of velocity and pressure.
The mesh generation is done using the GAMBIT code.
The boundary layer is dened as the rst row of
0.015 mm with a growth factor of 1.5 and includes 4 rows.
The mesh size is about 0.2 mm for all model regions except
for the boundary layer.
Thermo-physical properties of uids were calculated by
using PROPATH [6]. The uid is assumed to be in local
equilibrium for thermodynamic and transport properties.
Free convection, viscous dissipation and compressive work
are neglected in the simulation.
The simulation is performed for about 3000 iterations to
obtain the convergence of continuity, velocity, energy, and
turbulence.
2.4. Simulation conditions
The working uid of the heat pump is a supercritical
carbon dioxide (CO2) of 11.5 MPa where inlet and outlet

temperatures are 118 C and 16 C, respectively. The hot

CO2 heats cold water from 7 C to 90 C. The hot and cold
ows are arranged in a counter-current ow scheme. The
operating condition was determined to avoid the pinch
point, as shown in Fig. 4. The minimum temperature dierence between hot and cold uids is ca. 5 C. These operating conditions are summarized in Table 1 as the simulation
conditional performance.
3. Results and discussion
3.1. Hydraulic diameters of hot and cold side
In a previous study, the S-shaped n angle was selected
as 52, judging from the pressure drop and heat transfer
performance [1]. In this study, n size and channel hydraulic diameters are determined in the CO2 channels and H2O
channels for a hot water supplier system.
The hydraulic diameter of the CO2 channels was changed from 0.55 mm to 1.92 mm changing the ow channel
depth and n gap as given in Table 2. The thermalhydraulic performance was evaluated at the n angle of 52, n
length of 4.8 mm and n width of 0.4 mm changing the
hydraulic diameter. The relationships of pressure drop
and heat transfer rate per unit volume to the hydraulic
diameter are demonstrated in Fig. 5. The hydraulic diameter of Dh = 0.61 mm was selected as reference design

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T.L. Ngo et al. / Experimental Thermal and Fluid Science 30 (2006) 811819

Table 2
Hydraulic diameter of the CO2 side
0.47
0.87
0.61

1.8

0.71
0.87
0.78

0.94
1.31
1.09

1.05
1.97
1.37

1.28
2.29
1.64

1.51
2.65
1.92

60

Heat transfer rate per unit volume

Pressure drop per unit length

50

1.6
1.4

14

1.2
1.0

12
0.8
0.6

10

0.4

40

30

0.2
3.56

3.6

0.0
4.0

4.4

4.8

5.2

5.6

6.0

6.4

6.8

Hydraulic diameter of H2O side, Dh (mm)

20

Fig. 6. Heat transfer and pressure drop performance in the H2O side with
hydraulic diameter.

10

0.61
0.4

0.6

0.8

1.0

1.2

1.4

1.6

1.8

2.0

Hydraulic diameter of CO2 side, Dh (mm)

Fig. 5. Heat transfer and pressure drop performance in the CO2 side
hydraulic diameter.

Items

CO2 side

H2O side

Fin angle
Fin length (mm)
Fin width (mm)
Channel depth (mm)
Fin gap (mm)
Dh (mm)

52
4.8
0.4
0.47
0.87
0.61

52
14.4
1.2
2.5
6.17
3.56

67.98

(a) Single banking

(b) Double banking

6.58

considering the heat transfer rate and pressure drop performance.

The hydraulic diameter of the H2O channels was also
changed from 3.56 mm to 6.72 mm under the conditions
given in Table 3 at the n angle of 52, n length of
14.4 mm and n width of 1.2 mm. The smaller hydraulic
diameter yields better heat transfer performance, as shown
in Fig. 6, but water channel diameter must be suciently
large to avoid channel blockage resulting from scale deposition from city water at temperatures higher than 60 C.
Consequently, the water channels hydraulic diameter was
selected as 3.56 mm, which provides a slightly lower pressure drop than the target on (20 kPa) of the existing hot
water supplier for residential use [7]. The n design parameters are summarized in Table 4.

Table 4
Fin design parameters

3.85

4.75

Q/V (MW/m3); P (kPa/m)

16

Q/V, (MW/m3)

0.47
0.66
0.55

P , (kPa/m)

Channel depth (mm)

Fin gap (mm)
Dh (mm)

2.0

18

3.2. Plate conguration

(c) Quadruple banking

8.40

The H2O side plate with four channels can be surrounded by one CO2 side plate (single-banking), two plates
(double-banking), four plates (quadruple-banking) or six
plates (hexadic-banking), as illustrated in Fig. 7. The n
conguration, with the hot side ns (gray) superimposed
on the cold side ns (black), are shown in Fig. 8. The bank: CO2 channel:

2.5
6.17
3.56

3.0
6.42
4.09

: H2O channel

Fig. 7. Plate banking models.

Table 3
Hydraulic diameter of the H2O side
Channel depth (mm)
Fin gap (mm)
Dh (mm)

Unit: mm

(d) Hexadic banking

4.0
6.42
4.93

5.0
6.42
5.62

5.0
10.22
6.72

ing model dependency on the heat transfer performance

and pressure drop are investigated both analytically and
numerically.

T.L. Ngo et al. / Experimental Thermal and Fluid Science 30 (2006) 811819
350

CFD Simulation
Analytical calculation
CFD simulation
Analytical calculation

44
42
40

300
250

38
36

200

34

150

32

P, (kPa/m)

Q/V, (MW/m3)

815

100

30
28 Reference

50

26 design
0

Number of CO2 per H 2O plate

Fig. 9. Heat transfer and pressure drop performance with banking
models.

Fig. 8. Hot and cold plate conguration: (gray) CO2 side ns and (black)
H2O side ns.

The overall heat transfer coecient for the single banking (U1) model is given below.
U1

1
1
Ah;1 Dtw
Ah;1

hh;1
Aw k
Ac;1 hc;1

Similarly, the overall heat transfer equation for J-banking (UJ) is expressed in Eq. (4), assuming that the local heat
transfer coecient is proportional to the 0.8 power of the
Reynolds number (h / Re0.8) according to the power law
relationship Nu / Re0.8 [8,9] commonly used for heat
transfer of fully developed turbulent ow. Recently this
relation was found to be applicable to turbulent and laminar ows in the PCHE hot water supplier [10].
1
1
UJ

1
Ah;j Dtw
Ah;j
1
JAh;1 Dtw
JAh;1

hh;J
Aw k
Ac;j hc;j hh;1 J 0:8
Aw k
Ac;1 hc;1
4
The volume ratio of the J-banking heat exchanger to the
single banking model is expressed as Eq. (5).
0 1
JAh;1 Dtw
JAh;1 1
0
1

Vh
0:8
Aw k
Ac;1 hc;1 C
V J @ 1 J V c AB
hh;1 J
C

 B
5

@
A
V
1
A
Dt
A
VI
h;1
w
h;1
J 1 V hc

hh;1
Aw k
Ac;1 hc;1

Heat transfer and pressure drop performance with the

banking models are shown along with numerical and analytical results in Fig. 9. Good agreement pertains between
the analytical estimations and the numerical calculation
results.
The double-banking design (number of the CO2 plate
per the H2O plate = 2) is chosen as the reference design
by considering the pressure drop and heat transfer performance, as demonstrated in Fig. 9.
3.3. Thermal hydraulic performance
The ow velocity distribution in the double-banking
model that was obtained from the FLUENT calculations
is illustrated in Fig. 10 for the CO2 side. Flow velocity proles at the cross section lines (1)(17) in Fig. 10 are provided in Fig. 11. The velocity distribution at cross
sections (1) and (2) are almost identical to those of cross
sections (16) and (17), as shown in Fig. 11(a).
The ow between ns D and B merges with ow
between the ns B and E, which becomes the ow between
ns D and E. Similarly, the ow between ns C and A
merges with the ow between ns A and D, which creates

Similarly, the pressure drop ratio per unit length of the

J-banking model to the single banking model is expressible
as follows, assuming that the friction pressure loss factor is
proportional to the 0.2 power of the Reynolds number
(f / Re0.2) [11].
DP I / LfG2
DP J
J 1:8
DP I

6
7
Fig. 10. Vector of uid ow velocity in CO2 channel.

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T.L. Ngo et al. / Experimental Thermal and Fluid Science 30 (2006) 811819
5

1600
Section(16)
Section(17)

Flow velocity, (m/s)

4
3.5
3
2.5
2
1.5
1
0.5
0
0

(a)

0.2

0.4

0.6

0.8

1.2

1.4

1.6

1.8

Local heat transfer coefficient,

h, (W/m2K)

Section(1)
Section(2)

4.5

Lower wall surface of fin D

Upper wall surface of fin D

1400
1200
1000
800
600
400
200

Distance from upper surface of fin B and G, (mm)

0
4.5

Flow velocity, (m/s)

3.5

10

11

12

13

14

Section number

Section(3)
Section(4)
Section(5)
Section(6)

Fig. 12. Local heat transfer coecient.

3
2.5
2
1.5
1
0.5
0

0.2

(b)

0.4

0.6

0.8

4.5

1.2

1.4

1.6

1.8

Section(7)
Section(8)
Section(9)
Se ction(10)

Flow velocity, (m/s)

Distance from upper surface of fin B, (mm)

3.5
3
2.5
2
1.5
1

channel conguration. The local heat transfer coecient

around surfaces of n D was evaluated from the FLUENT
calculations, as shown in Fig. 12. This n shape yields more
heat transfer points than those obtained by a conventional
zigzag ow channel. In the zigzag ow channel, transferred
heat is enhanced only at the corners [1], but pressure drop
is strongly increased by corner and its number. The corner
also yields eddies and reversed ow at small angles, which
increase pressure drop. In this S-shaped n, transferred
heat is enhanced around the wall surfaces, particularly at
the convex face near the sinusoidal peaks (sections (9),
(10) of lower wall) and at the heads (sections (3)) and
near the tails of ns (sections (13) and (14) of the upper
wall), as shown in Figs. 10 and 12. No reversed ow or
eddies are observed in this channel conguration, as
explained above.

0.5
0

3.4. Heat exchanger size evaluation

0

0.5

1.5

2.5

3.5

Distance from upper surface of fin E, (mm)

(c)
4

Section(11)
Section(12)
Section(13)
Section(14)

3.5

Flow velocity, (m/s)

3
2.5
2
1.5
1
0.5
0

(d)

0.5

1.5

Distance from upper surface of fin H, (mm)

Fig. 11. Flow velocity proles in sections (1)(17).

in the ow between the ns C and D. Fig. 11(c) shows that

ows between ns C and D and between D and E, have
almost equal ow velocity distributions.
The local heat transfer coecient is also examined to
determine how heat transfer can be enhanced in this new

Because of the large specic heat dependency of CO2 on

temperature, as shown in Fig. 13, the temperature and its
dierence between the hot and cold channels have nonlinearity with the distance from the hot side inlet, as
illustrated in Figs. 4 and 14, respectively. Therefore, the
Logarithmic Mean Temperature Dierence (LMTD) cannot be applied to evaluation of thermalhydraulic performance. However, the entire PCHE cannot be simulated
at one calculation because of limitations of the computer
memory and computing time. For that reason, the whole
PCHE was divided into M parts (M P 2).
The overall heat transfer coecient, U(Q), for each part
of the PCHE is calculated from Eq. (8):
Z QCFD
m1
dQ
Um
8
A
CFD DT Q
Qm
where DT(Q) is the temperature dierence between the hot
and the cold uid, as shown in Fig. 14. Then U(Q) is expressed as a polynomial function using a least-squares
method from U1, . . . , Um. In this study, the entire PCHE

T.L. Ngo et al. / Experimental Thermal and Fluid Science 30 (2006) 811819
6000

Overall heat transfer coefficient, U

Polynomial fit of U
1650

H2O (P = 0.25 MPa)

1600
2

Overall HTC, U (W/m K)

Specific heat, cp (J/kgK)

CO2 (P= 11.5 MPa)

5000

4000

3000

2000

817

1550
1500
1450 U =1526.696-0.035 Q
-4

-12

-8

1400

+1.07810 Q -3.144 10 Q

1350

-1.099 10 Q +5.74410 Q

-16

1300
1000
0

20

40

60

80

Temperature,

100

120

CO2 Inlet

T(oC)

H 2O Outlet

1000

2000

3000

4000

Heat Load, Q (W)

5000

CO2 Outlet
H 2O Inlet

Fig. 13. Specic heat as a function of temperature.

Fig. 15. Overall heat transfer coecient of PCHE.

Table 5
New PCHE vs. existing hot water supplier
Items

Temperature difference, T ( C)

30
25

CO2 side
Dimension (mm)
Plate no.
Channel no.
A (m2)
L (mm)
Re
DP (kPa)
Q/V (MW/m3)
Volume ratio

20
15
10

New PCHE

2
3

10

Existing
H2O side

W214 H440 D10

2
1
54
4
0.309
0.146
1240
11,092
1176
95
4
4.9
1

CO2 side

H2O side

W260 H560 D20

2
2
0.282

14,000

19,969
1365
ca. 150
42
1.5
3.3

0
0
CO2 Inlet

1000

H2O Outlet

2000

3000

Heat load, Q(W)

4000

5000
CO2 Inlet
H2O Outlet

Fig. 14. Temperature dierence as a function of heat load.

was divided into 10 zones, as depicted in Fig. 14. In Fig. 15,

U(Q) at each zone and the polynomial function are given.
Thereby, the total heat exchanger area is estimated
from:
Z Qtot
dQ
Atot
9
U QDT Q
0
Finally, the total number of channels for the CO2 and
H2O sides and active heat exchanger length are determined
respectively using Eqs. (10) and (11)
W tot nCFD
W CFD
Atot LCFD nCFD

ACFD ntot

air gap with 5 mm width, as illustrated in Fig. 16(a)(c).

The right and left margins are 5 mm, and the top and bottom plates thicknesses are 2.5 mm.
Table 5 presents a comparison of the 4.6 kW heat
exchanger size for a hot water supplier between the new
PCHE and an existing hot water supplier for a residential
use [7]. For equal heat capacity, the PCHE attains compactness of 4.9 MW/m3 that is 3.3 times higher than the
existing 1.5 MW/m3 hot water supplier. The PCHE provides lower pressure drop by 37% in the CO2 side and by
10 times smaller in the H2O side. Therefore, the new PCHE
volume is 3.3 times less than that of conventional hot water
supplier. The promising thermalhydraulic performance of
the new PCHE has been conrmed in a mockup test loop
for the heat recovery system, as shown in Fig. 17.

ntot

10

4. Conclusions

Ltot

11

The new PCHE with S-shaped ns provides 3.3 times

smaller volume than that of the existing hot water supplier.
It also provides lower pressure drop by 37% in the CO2 side
and by ten times smaller in the H2O side. The promising
thermalhydraulic performance of the new PCHE has been
conrmed by using the heat recovery test facility.

The total number of channels and the active heat

exchanger length are given in Table 5. The whole PCHE
length of 1.24 m is too long for use in a straight structure.
Therefore, it is folded in three having a thermal insulation

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T.L. Ngo et al. / Experimental Thermal and Fluid Science 30 (2006) 811819

Fig. 16. New PCHE hot water supplier (Unit: mm).

T.L. Ngo et al. / Experimental Thermal and Fluid Science 30 (2006) 811819

[2]

[3]

[4]

[5]
[6]

[7]

[8]
Fig. 17. Heat recovery test facility.

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