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Department of Refrigeration and Cryogenics Engineering, School of Energy and Power Engineering, Xian Jiaotong University, Xian 710049, China
Received 25 November 2003; received in revised form 19 March 2004; accepted 30 April 2004
Abstract
In order to enhance the uniformity of ow distribution, an improved header conguration of plate-n heat exchanger is put
forward in this paper. Based on the analysis of the uid ow maldistribution for the conventional header used in industry, a bae
with small holes of three dierent kinds of diameters is recommended to install in the header. The ow maldistribution parameter S
is obtained under dierent header conguration. When the bae is properly installed with an optimum length, with stagger arranged
and suitably distributed holes from axial line to bae boundary, the ratio of the maximum ow velocity to the minimum ow
velocity drops from 3.443.04 to 1.571.68 for various Reynolds numbers. The numerical results indicate that the improved header
conguration can eectively improve the performance. The conclusion of this paper is of great signicance in the improvement of
plate-n heat exchanger.
2004 Elsevier Ltd. All rights reserved.
Keywords: Plate-n heat exchanger; Flow maldistribution; Optimum design
1. Introduction
Plate-n heat exchangers are widely used in process
industries such as air separation and petrochemical
industries to exchange heat energy among more than
two uids with dierent supply temperatures because of
their higher eciency, more compact structure and
lower costs than two-stream heat exchanger networks.
The use of multi-stream plate-n heat exchangers is
more cost-eective and can oer signicant advantages
over conventional two-stream heat exchangers in certain
applications, especially in cryogenic plants [13]. In the
design of plate-n heat exchanger, it is usually presumed
that the inlet ow and temperature distribution across
the exchanger core are uniform and steady. However,
the assumption is generally not realistic under actual
operating conditions due to various reasons. One of
*
Corresponding authors. Tel.: +86-29-8266-3725; fax: +86-29-82668725 (J. Wen); tel.: +86-29-8266-8725; fax: +86-29-8266-8789 (Y. Li).
E-mail addresses: wenjian@mailst.xjtu.edu.cn (J. Wen), yzli-epe@
mail.xjtu.edu.cn (Y. Li).
0011-2275/$ - see front matter 2004 Elsevier Ltd. All rights reserved.
doi:10.1016/j.cryogenics.2004.04.009
824
Nomenclature
A
A0
A1
A2
A3
C
D
f x
H
h
L
N
Ntu
Ntu; n
Ntux
R
Re
Rx
model in paired-channel heat exchangers and investigated the eect of ow maldistribution on the performance deterioration. Based on the experimental data
obtained from wind tunnel experiments, Chiou [6] set up
a continuous ow distribution model and studied the
thermal performance deterioration in cross-ow heat
exchangers. Ranganayakulu and Seetharamu [7] investigated the eect of inlet ow nonuniformity on thermal
performance and pressure drops in crossow plate-n
heat exchangers using nite element method.
It must be noted that all of the above works mainly
concentrated on the eect of ow nonuniformity on the
heat exchanger performance. The literature of improved conguration to enhance the ow uniformity in
plate-n heat exchanger is little in recently years. Lalot
and Florent [8] studied the gross ow maldistribution
in an electrical heater and found that the perforated
grid can improve the uid ow distribution. Jiao [9]
investigated experimentally and analyzed theoretically
the combined eects of distributors inlet angle, conguration parameter h=H and header conguration on
ow velocity distribution. Zhang [10] proposed a
structure of two-stage-distribution and the numerical
investigation shows the ow distribution in plate-n
heat exchanger is more uniform if the ratios of outlet
and inlet equivalent diameters for both headers are
equal. In this paper, a simple way is put forward to
homogenize the ow distribution. A bae with smallsize holes is installed in the traditional header to optimize the header conguration. The investigation on the
eect of the conguration of the bae on the ow
distribution is presented.
S
SI
T
v
d
e
ex
Subscripts
ave
average value
c
cold uid
ch
channel
h
heat uid
i
serial number of passage
i
inlet
max
maximum value
o
outlet
Z
Inlet tube
Header
Y
X
825
Inlet tube
Channel 11
Channel 22
Channel 33
Small passages
3 5 7
9 11
13 15 17
19 21 23
25 27 29
31 33
35 37 39
41 43
0
0
50
100
150
200
250
300
Location (mm)
Fig. 3. Outlet velocity of channels along with y direction.
1.0
4
Re=1.010
5
Re=1.010
6
Re=1.010
0.8
0.6
0.4
0.2
0.0
-0.2
-0.4
-0.6
-0.8
-1.0
0
10
20
30
40
50
826
R
boundary. It is presumed that v dA is equal to a constant value under ideal condition. Thus the uid ow is
distributed uniformly before it reaches the header outlet
and the expected object of uniformly distribution is
achieved.
The bae congurations are demonstrated in Figs. 6
and 7. The baes have the dimension of 670 260 5
mm3 (length width height), on which three dierent
kinds of holes in diameter are punched. There are
spotted symmetrically small (2R 10 mm), medium
(2R 20 mm) and big (2R 30 mm) holes from the
axial line to the boundary on the bae. In Fig. 6 the
bae with holes distributed in line arrangement is denoted as conguration B while in Fig. 7 the one with
holes distributed in stagger arrangement is denoted as
conguration C.
The numerical results according to the bae congurations B and C are demonstrated in Figs. 8 and 9,
respectively, under dierent inlet Reynolds numbers.
The headers with baes have more uniform velocity
distribution at outlet. The relative maldistribution
parameter Si is )0.280.59 for conguration B with inline arrangement and )0.230.30 for conguration C
with staggered arrangement, which are much smaller
than those of conguration A ()0.430.81). For the
improved congurations, the velocities increase in the
zone of two ends of header and decrease in the zone near
the axial line. Thus, the uid ow is distributed more
uniformly. Unfortunately the pressure drop may increase and result in the decrease of mean velocities to
some extent, which is inevitable but not anticipated. So
it is obliged to get the suitable bae conguration, such
Baffle
827
1.0
Re=1.0 104
Re=1.0 105
Re=1.0 106
0.8
0.4
0.2
0.0
-0.2
-0.4
-0.6
-0.8
-1.0
0
10
20
30
40
50
1.0
Re=1.0 104
Re=1.0 105
Re=1.0 106
0.8
0.6
Si=(vch(i)-vave)/vave
0.4
0.2
0.0
-0.2
-0.4
-0.6
-0.8
-1.0
0
10
20
30
40
50
Si=(vch(i)-vave)/vave
0.6
0
0
10
20
30
40
50
Absolute maldistribution S
600
0.5
400
200
0
2
0.3
0.2
Flow maldistribution
Average velocity
-400
0.0
0.45
10
20
30
40
0.1
Type A
Type B
Type C
-200
0.4
50
828
0
0.50
0.55
0.60
0.65
0.70
0.75
0.80
ow resistance brought about by bae necessarily decreases. Moreover, the increase of punched ratio leads to
the increase of ow area on the bae and further results
in the decrease of absolute maldistribution parameter S.
Fig. 11 shows the pressure drop distribution for dierent
headers. It can be seen from the gure that the improved
conguration has better pressure distribution, the average pressure drop of conguration C is smaller than that
of conguration B for its smaller ow resistance. Negative pressure drops happen for conguration A in the
center part, which is due to the ow stagnation in the
isolation zone of the header outlet and the ow dynamic
head compensates for the hydrostatic head.
It can be concluded from Figs. 10 and 11 that the
bae with stagger arranged holes is suitable to improve
the ow distribution in header. The ow distribution is
more uniform and the pressure drops are smaller. The
improvement of header conguration with a stagger
arranged bae should be selected rstly.
A2
:
A1 A2 A3
500
400
300
1
Pressure drop
Average velocity
200
Actual curve
Expected curve
Punched ratio (%)
600
70
700
829
60
50
100
0
0
0.25
0.30
0.35
0.40
0.45
0.50
average velocity reaches an extreme point at the adjacent of area ratio A0 0:33. For the header with conguration C, it is suitable when area ratio is equal to
0.33, namely the total area of medium-size holes takes
up 1/3 of the whole area of all the holes.
4.4. The eect of punched ratio
When the bae conguration is determined, the
average velocity of conguration C is larger than that of
conguration A due to the decrease of the highest uid
velocity. For conguration C, the velocity distribution is
mostly concentrated in the range of 2.54.0 m/s. The
numbers of passages with the ow velocity between 2.5
and 4.0 m/s takes about 72% of the whole passages at
Re 1:0 105 . While for conguration A, the velocity
distribution is concentrated between 1.0 and 2.5 m/s,
which takes about 65% of the numbers of whole passages. The ow velocity ratio of the maximum to the
minimum drops from 3.443.04 of conguration A to
1.571.68 of conguration C, which reects a more
uniform ow for the improved header. From the above
discussion, the eect of header congurations on ow
maldistribution is prominent. The ow velocity of the
passages near the boundary can be enhanced eectively
by changing the header conguration from A to C. It is
also possible to modify the velocity ratio by depending
on the pressure loss coecient of the bae. The ow
velocity distribution of conguration C gives the most
uniform result among the cases considered in this paper.
From the above discussion, it can be concluded that
the determination of bae conguration has the relationship with the diameter of inlet tube, the length and
diameter of header, the diameters and distribution of
holes when the bae installation location has been dened. Fig. 14 shows the distribution of punched ratio, in
which the staircase curve is drawn according to the
40
-400
-300
-200
-100
100
200
300
400
X position (mm)
Fig. 14. Punched ratio versus x position along with the bae length
for conguration C.
1.0
Type A
Type B
Type C
0.9
Effectiveness,e
830
0.8
0.7
1 eNtux1Rxi
1 Rxi eNtux1Rxi
0 6 x 6 1; Rxi < 1;
when 0 6 x 6 x
when x 6 x 6 1 :
7
mi Th;o x
P
:
mi
ex
f x dx
exf x dx;
mave
x
0
10
where
f x
xa1 1 xb1
Ba; b
Ba; b
0 6 x 6 1;
11
12
mchi
mmax
and x
mave
:
mmax
40
50
60
70
80
90
100
Ntu
6
(
0.6
13
When the Ntu of heat exchanger is given, the theoretical value Ntu; n of every channel is equal to Ntu from
its concept. The velocity mchi of every channel and the
average velocity mave can be obtained from CFD simu-
6. Conclusions
The performance of uid ow distribution in the
header of plat-n heat exchanger has been calculated
and analyzed. It is found that the uid ow maldistribution is very serious in the direction of header length
for the conventional header used in industry due to poor
header conguration. Based on the analysis of the uid
ow maldistribution, a bae with small-size holes is
recommended to install in the header in order to improve the performance of ow distribution. The results
of calculation indicate that the improved header conguration can eectively enhance the uid ow uniformity. The ow absolute maldistribution parameter S in
plate-n heat exchanger has been reduced from 0.95 to
0.32 by installing the bae. When the bae is proper in
length, the holes are distributed in staggered arrangement, and the punched ratio gradually increases from
axes along with the dam board length, the ratio of the
maximum ow velocity to the minimum ow velocity
may drop from 3.443.04 to 1.571.68 for various
Reynolds numbers. The uid ow distribution in platen heat exchanger is more uniform by the optimum
design of the header conguration. And through a
rough calculation, it is quantitatively shown that the
improved header conguration can prominently improve the performance of plate-n heat exchangers.
The bae is lower in cost and convenient in assembly, while the eect of the uid ow distribution uniformly by the improved conguration is obvious. The
conclusion of this paper is of great signicance in the
improvement of plate-n heat exchanger.
Acknowledgement
The authors would like to thank the Ministry of
Education, PR China for its nancial support.
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