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Heat Transfer Engineering

ISSN: 0145-7632 (Print) 1521-0537 (Online) Journal homepage: https://www.tandfonline.com/loi/uhte20

A Parametric Study of the Thermal-Hydraulic


Performance of a Zigzag Printed Circuit Heat
Exchanger

Sang-Moon Lee & Kwang-Yong Kim

To cite this article: Sang-Moon Lee & Kwang-Yong Kim (2014) A Parametric Study of the
Thermal-Hydraulic Performance of a Zigzag Printed Circuit Heat Exchanger, Heat Transfer
Engineering, 35:13, 1192-1200, DOI: 10.1080/01457632.2013.870004

To link to this article: https://doi.org/10.1080/01457632.2013.870004

Published online: 06 Feb 2014.

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Heat Transfer Engineering, 35(13):1192–1200, 2014
Copyright 
C Taylor and Francis Group, LLC
ISSN: 0145-7632 print / 1521-0537 online
DOI: 10.1080/01457632.2013.870004

A Parametric Study of the


Thermal-Hydraulic Performance
of a Zigzag Printed Circuit Heat
Exchanger

SANG-MOON LEE and KWANG-YONG KIM


Department of Mechanical Engineering, Inha University, Incheon, Korea

The effects of geometric parameters on the performance of a printed circuit heat exchanger have been analyzed using three-
dimensional Reynolds-averaged Navier–Stokes equations. The shear stress transport model is used for accurate prediction of
the turbulent flows. The numerical solutions are validated in comparison with the available experimental data, and different
lengths of the calculation domain have been tested to determine the optimum length of the domain. The effects of two design
parameters, namely, the channel angle and the semi-ellipse aspect ratio of the cold channel, on the heat transfer and friction
performance in the cold channel have been evaluated. The results indicate that the effectiveness of the heat exchanger is
maximized when the cold channel angle is similar to the hot channel angle.

INTRODUCTION transfer surface to heat exchanger volume), is a heat exchanger


suitable for high-temperature gas cooled reactors.
High-temperature, gas-cooled nuclear reactors with a closed Figure 1 shows the outline of a PCHE stack. As shown in
gas turbine cycle are being considered as a nuclear power gen- this figure, each flow channel is made through chemical etching
eration concept for the future. In theory, the gas turbine cycle on the surface of metal plates. By connecting metal plates with
has an advantage in terms of simplicity and efficiency compared a diffusion bond and large-scale integration, it is possible to
to the steam turbine cycle [1], but has the disadvantage of high enable the PCHE to operate under high pressure. The channels
turbine inlet pressure, and the cycle is in the small-scale test- on each plate have a zigzag shape that causes high pressure loss.
ing phase so not available commercially. The durability of each This pressure drop should be reduced, as a high pressure loss
component of the gas turbine cycle should be guaranteed due may cause a high operating cost for the power plant. Another
to high-temperature and high-pressure environments. In addi- important parameter of concern is the heat exchanger efficiency
tion, since gas is used as the working fluid, inefficiency due to of the PCHE. In order to optimize the performance of the PCHE,
large volumes is inevitable in the case where a heat exchanger it is necessary to compromise between different performance
is used as a recuperator and precooler. In this respect, there has parameters, such as the efficiency and pressure drop based on
been a need for the development of new heat exchangers that thermal-hydraulic analysis.
have higher heat transfer performance with sufficient durabil- Various studies on PCHEs have been performed both ex-
ity compared to the conventional ones. One of the new heat perimentally and numerically. Ishizuka et al. [3] performed
exchangers is the printed circuit heat exchanger (PCHE), de- experiments regarding a PCHE with zigzag channels. They
veloped by HEATRIC [2]. The PCHE, which has excellent heat obtained the characteristics in terms of thermal performance
transfer performance due to a large area density (the ratio of heat and pressure drop of supercritical carbon dioxide (CO2 ) in the
PCHE under variations in the flow rate, pressure, and tempera-
ture. Ngo et al. [4] used three-dimensional Reynolds-averaged
Address correspondence to Professor Kwang-Yong Kim, Department of Me- Navier–Stokes (RANS) analysis to compare the performance of
chanical Engineering, Inha University, 253 Yonghyun-Dong, Nam-Gu, Incheon, a PCHE channel with an S-shaped fin with that of the reference
402-751, Korea. E-mail: kykim@inha.ac.kr PCHE channel for a hot-water supplier. Kim et al. [5] performed

1192
S.-M. LEE AND K.-Y. KIM 1193

The Shear Stress Transport (SST) model [13] with automatic


wall treatment is used for predicting turbulent flows in the zigzag
PCHE channel. The SST model combines the advantages of the
k-ε and k-ω models with blending functions. The k-ω model is
activated in the near-wall region, and the k-ε model is used in the
region far from the wall. Bardina et al. [14] reported that the SST
model efficiently captures separation under an adverse pressure
gradient compared to other eddy viscosity models. To construct
the volume meshes, unstructured tetrahedral meshes were used
in most of the computational domain, but prism meshes were
used near the walls. Second-order-accurate schemes were se-
lected for discretizing the governing equations. A turbulent in-
tensity of 5% and an autocomputed length scale were selected
for the inlet turbulence condition. The first grid points adjacent
to the walls were placed at y+ less than 1.0, which is required
to implement the low-Reynolds-number SST model.
Figure 1 Plate stacking prior to diffusion bonding [2]. As shown in Figure 1, each plate has the flutes of hot or cold
zigzag channels, and these plates are stacked on each other to
form a PCHE. The calculation domain in Figure 2 [15] was set
three-dimensional numerical analyses of a zigzag PCHE and an
by considering repeated cross sections. Figures 3 [15] and 4
airfoil-shaped fin PCHE, and showed that the airfoil-shaped fin
[15] show the geometry of the zigzag PCHE. The dimensions
PCHE has almost the same total heat transfer rate per unit vol-
of the reference geometry [3] of the zigzag PCHE are given in
ume and decreased pressure drop compared to the zigzag PCHE.
Table 1. As shown in Figure 4, the entire computational domain
Nikitin et al. [6] investigated the heat transfer and pressure drop
consisted of three parts: cold channels, hot channels, and a steel
characteristics of a PCHE in an experiment with a supercriti-
substrate. Conjugate heat transfer that consists of convective
cal carbon dioxide loop. Pra et al. [7] constructed a numerical
heat transfer in the cold and hot channels and heat conduction
model from the validation results for PCHEs, and obtained a
in the substrate was analyzed in this work. Periodic conditions
suitable operating condition by using the results of various ac-
were used on the upper and lower boundaries (z–x planes) and
cident scenario simulations. Kim et al. [8] obtained a numerical
on each side boundary (z–y planes). In the numerical analysis,
model for calculating the flow and heat transfer in PCHEs using
each domain was connected to the other domains using a domain
the GAMMA code [9] and three-dimensional numerical anal-
interface condition with general grid interface (GGI) [10].
ysis, and investigated the thermal hydraulic characteristics of
As shown in Figure 2, only a part of the PCHE was included
PCHEs.
in the calculation domain to reduce the computing time. The
As mentioned previously, many experimental and numerical
calculation domain was regarded as the part between 0.4 m and
studies have been carried out on PCHEs. This study deals with
the thermal-hydraulic analysis of a PCHE with zigzag chan-
nels using three-dimensional Reynolds-averaged Navier–Stokes
(RANS) and energy equations. The effectiveness and the pres-
sure drop in the PCHE are investigated with reference to geo-
metrical parameters, specifically, the cold channel angle and the
semi-ellipse aspect ratio of the cold channel.

NUMERICAL ANALYSIS

The present computational analyses were performed with the


commercial CFD code ANSYS CFX-11.0 [10], which employs
an unstructured grid to solve the governing equations for three-
dimensional steady turbulent flow and heat transfer in PCHEs.
The numerical analytic techniques introduced by Patankar [11]
and Ferziger and Peric [12] have been used for the analyses.
The working fluid used in this calculation is supercritical car-
bon dioxide, and the Reynolds number based on the hydraulic
diameter (1.089 mm) of the channel is 152,000. Figure 2 The calculation domain [15].

heat transfer engineering vol. 35 no. 13 2014


1194 S.-M. LEE AND K.-Y. KIM

Figure 4 Cross-section of the calculation domain of the PCHE [15].

Figure 3 Zigzag geometry of the channels in the PCHE [15].


tional domain employed in this work, the pressure-loss results of
the present computation were converted correspondingly. The
0.5 m on the z-axis of the PCHE model tested by Kim et al. [5] findings revealed that the present numerical results had relative
(Figures 5 and 6), and the boundary conditions were imposed errors of only 2–4% in comparison with the experimental data.
correspondingly from the experimental data [3] and reliable To determine the optimum number of meshes, a grid-
numerical data [5]. The working fluid used in this calculation dependency test was carried out for the cold channels of the
is supercritical carbon dioxide, and the Reynolds number based reference geometry of which the dimensions are given in Ta-
on the hydraulic diameter of the cold channel is from 67,000 to ble 1. As shown in Figure 8 [15], Grid II was selected as the
about 280,000 and the hot channel is 71,500. The temperatures optimum number of grids for the entire calculation domain.
at the inlet of the cold channels and the hot channels are 123◦ C A residual reduction factor of 10−8 was used for the conver-
and 138.2◦ C, respectively. Static pressure is specified at the gence of the iterative solutions. A personal computer with an
outlet of the channel: 8312 kPa for the cold channels and 2528 Intel I7 2.4 GHz CPU was used for the computations, and the
kPa for the hot channels. total time for getting each converged solution was in the range
In the preliminary stage of this study, to determine the length of 15–20 hrs.
(L) of the calculation domain shown in Figure 2, the lengths of
50 mm, 70 mm, and 100 mm were tested. As shown in Figure 7,
the temperature distribution with the length of 70 mm almost
coincided with that corresponding to 100 mm, and showed good PARAMETRIC STUDY
agreement with the experimental data of Kim et al. [5]. There-
fore, 70 mm was employed as the length of the calculation In the present parametric study of the PCHE, the nondi-
domain (L) in further calculations. mensional pressure drop and effectiveness have been used to
The numerical results for the pressure drop in the zigzag estimate the performance of the PCHE. The nondimensional
PCHE channels were also validated in comparison with the ex- pressure drop used to compute the pressure drop in the zigzag
perimental results presented by Ishizuka et al. [3], as shown in
Table 2. Since the length of the experimental equipment used
by Ishizuka et al. [3], 846 mm, was longer than the computa-

Table 1 Dimensions of the reference PCHE [3]

Parameter Value

Cold channel angle, θc 100◦


Cold channel height, hc 0.90 mm
Cold channel width, wc 1.90 mm
Cold channel wall thickness, tc 0.60 mm
Cold channel pitch length, Pc 7.24 mm
Hot channel angle, θh 115◦
Hot channel width, wh 1.80 mm
Hot channel wall thickness, th 0.70 mm
Hot channel pitch length, Ph 9.00 mm
Hot channel height, hh 0.95 mm
Figure 5 Temperature distributions in the hot and cold channels [5].

heat transfer engineering vol. 35 no. 13 2014


S.-M. LEE AND K.-Y. KIM 1195

Table 2 Results of validation of the computed pressure drops

Experimental data [3] Numerical results

Cold channel dp [Pa] 73,220 75,884


Hot channel dp [Pa] 24,180 24,776

where pin and pout are the static pressures at the inlet and outlet,
respectively, of the calculation domain of the zigzag PCHE
channel. Further, ρavg and vavg are the averaged CO2 density and
the averaged CO2 velocity in the channels, respectively.
The effectiveness of the zigzag PCHE channel is defined as
follows [5]:

Th,in − Th,out
η= . (2)
Th,in − Tc,in

where Th,in , Th,out , and Tc,in are the temperatures at the inlet
and outlet of the hot channel and the inlet of the cold channel,
respectively.
The effects of two geometric parameters, namely, the cold
channel angle (θc ) and the semi-ellipse aspect ratio of the cold
channel (αc ), as shown in Figures 3 and 4, on the PCHE’s
performance are also evaluated. The semi-ellipse aspect ratio of
the cold channel is defined as
wc
αc = . (3)
2h c

In the reference geometry, the cross-section shapes of the


cold channels are semicircles and the value αc is 1. The cross-
Figure 6 Pressure distributions in the hot and cold channels [5]: (a) cold
channel and (b) hot channel. section shapes of the cold channels are changed to semi-ellipse
according to αc variation. The values of wc had been varied with
fixed hc to find relationship between thermal-hydraulic perfor-
PCHE channel is defined as mance and αc . The variation of αc caused the variation of the cold
pin − pout channels that may affect the thermal-hydraulic performance of
f = , (1)
0.5ρavg vavg
2 PCHE. Therefore, αc had been selected for the parametric study.

Figure 7 Temperature distributions for different lengths of the calculation


domain. Figure 8 Results of the grid-dependency test [15].

heat transfer engineering vol. 35 no. 13 2014


1196 S.-M. LEE AND K.-Y. KIM

Figure 11 Pressure distribution inside the cold channels (0.2hc away from the
flat wall).
Figure 9 Velocity vector field in the cold channels (0.2hc away from the flat
wall).
served in the figure that the effectiveness tends to peak at a cold
channel angle of 110◦ and decreases as the cold channel angle
RESULTS AND DISCUSSION increases beyond that value. This indicates that the maximum
effectiveness occurs when the cold channel angle is similar to
Three-dimensional numerical analysis was first carried out the hot channel angle of 115◦ . Figure 13 [15] shows the effect
for the reference case of the PCHE. Figure 9 shows the velocity of the cold channel angle on the heat flux averaged over the
vector field in the cold channels located midway (0.47L – 0.53L) cold channel wall. It is found that the heat flux is maximized
in the calculation domain. This pattern of the vector field is at 130◦ . The reason for this phenomenon can be found through
repeated over two bending parts. It can be observed that flow the velocity vector field in the cold channels of the PCHE in
separation zones occur near the bending parts of the channels. Figure 14 and the heat flux distribution on the cold channel wall
The heat flux distribution on the flat wall of the cold channel is in Figure 15 [15]. As shown in these figures, the overall heat
shown in Figure 10. It is seen from Figures 9 and 10 that high flux is increased by the reduction in the separation zone with an
heat flux occurs in the region of high flow velocity. That is, it increase in the cold channel angle from 90◦ to 130◦ . However,
can be inferred that the overall heat flux will increase with a further increase in the cold channel angle decreases the overall
reduction in the separation zone and an increase in the region heat flux. With increase in the angle the separation zone angle is
of high velocity. On the other hand, Figure 11 shows the static decreasing, which leads to maximum mixing at 130◦ , and then
pressure distribution in the cold channels of the PCHE. It can any further increase in angle leads to reduction in mixing or less
be seen that high pressure gradients due to high pressure loss turbulent regime.
are found near the bending parts. Figure 16 shows the variation of the nondimensional pressure
When testing each parameter, the rest of the parameters were drop, f , with the cold channel angle. This figure clearly shows
fixed at the values listed in Table 1. In the case of the aspect that the nondimensional pressure drop decreases monotonically
ratio, the cross-sectional area of the channel was fixed. with the cold channel angle, which results from a contraction
in the separation zone near the bending parts of the channel,
as shown in Figure 14. Figure 17 shows the effect of the cold
Effect of the Cold Channel Angle

Figure 12 [15] shows the effect of the cold channel angle, θc ,


on the effectiveness, η, in the range 90◦ < θc < 180◦ . It is ob-

Figure 12 Effect of the cold channel angle on the effectiveness of the zigzag
Figure 10 Heat flux distribution on the flat wall of the cold channel. PCHE.

heat transfer engineering vol. 35 no. 13 2014


S.-M. LEE AND K.-Y. KIM 1197

Figure 13 Effect of the cold channel angle on the heat flux of the cold channel.

Figure 15 Heat flux distribution on the flat wall of the cold channel: (a) 90◦ ;
(b) 130◦ ; and (c) 150◦ .

Figure 14 Velocity vector field in the cold channels (0.2hc away from the flat Figure 16 Effect of the cold channel angle on the nondimensional pressure
wall): (a) 90◦ ; (b) 130◦ ; and (c) 150◦ . drop of the cold channel.

heat transfer engineering vol. 35 no. 13 2014


1198 S.-M. LEE AND K.-Y. KIM

Figure 17 Effect of the cold channel angle on the pressure distribution. Figure 19 Effect of the semi-ellipse aspect ratio of the cold channel on the
heat flux [15].

channel angle on the pressure distribution in the cold channel.


As shown in this figure, the pressure distribution in the cold decreases as shown in Figure 19. On the other hand, a decrease
channel becomes more linear when the area of the separation in the aspect ratio also causes a decrease in the heat flux because
zone decreases with an increase in the cold channel angle and the area close to the hot channels is decreased. Figure 21 [15]
the pressure drop decreases as the angle increases. shows the variation of the nondimensional pressure drop with
the semi-ellipse aspect ratio of the cold channel. The nondimen-
sional pressure drop increases with αc . Hence, a lower αc yields
Effect of the Semi-Ellipse Aspect Ratio better friction performance than a higher αc .

The semi-ellipse aspect ratio of the cold channels also has


some effect on the heat transfer rate and the pressure drop. To
test these effects, calculations have been performed in the range,
0.5 < αc < 1.5. The variation of the effectiveness of the PCHE
with the semi-ellipse aspect ratio of the cold channel, αc , is
shown in Figure 18 [15]. It is found that as αc increases, the
effectiveness also increases. Figure 19 [15] shows the variation
of the average heat flux in the cold channel with αc . This figure
shows the optimum semi-ellipse aspect ratio of the cold channel
as being near 1.0, which yields the maximum heat flux. Fig-
ure 20 shows the velocity contours in the cold channels. As the
aspect ratio increases from 1.0 to 1.5, the velocities around the
bending parts of the channel reduce; therefore, the heat flux also

Figure 18 Effect of the semi-ellipse aspect ratio of the cold channel on the Figure 20 Velocity contours in the cold channels (0.2hc away from the flat
effectiveness of the PCHE [15]. wall).

heat transfer engineering vol. 35 no. 13 2014


S.-M. LEE AND K.-Y. KIM 1199

L length of the calculation domain


Pc cold channel pitch length
p pressure
T temperature
tc cold channel wall thickness
v velocity
w width of the channel
y+ dimensionless wall distance
z Cartesian coordinate z

Greek Symbols
α semi-ellipse aspect ratio of the channel
η effectiveness
θ channel angle
Figure 21 Effect of the semi-ellipse aspect ratio of the cold channel on the
ρ density
nondimensional pressure drop [15].

Subscripts
CONCLUSIONS
avg average
The pressure losses in the PCHE channels and the heat trans- c cold channel
fer performance are important determinants of the efficiency of h hot channel
the gas turbine cycle. A parametric study has been performed in inlet
regarding the effectiveness and pressure drop in the zigzag chan- out outlet
nels of a PCHE by using three-dimensional RANS analysis in
relation to two geometrical parameters: the cold channel angle
and the semi-ellipse aspect ratio of the cold channel. Different REFERENCES
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[8] Kim, I. H., No, H. C., Lee, J. I., and Jeon, B. [15] Lee, S. M., and Kim, K. Y., A Parametric Study on Fluid
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Sang-Moon Lee received his bachelor’s and mas-
bomachinery Models for High Temperature Gas-Cooled ter’s degrees in 2008 and 2010, respectively, at Inha
Reactors, 12th International Symposium on Trans- University, Korea. He is a Ph.D. student at the
port Phenomena and Dynamics of Rotating Machinery Computational Fluids Engineering Laboratory, Inha
(ISROMAC12), Honolulu, HI, ISROMAC12-2008-20224, University. Numerical analysis and optimization for
2008. printed circuit heat exchanger for high-temperature
gas-cooled reactors have been his major research in-
[10] CFX-11.0 Solver Theory, Ansys, Inc., Canonsburg, PA, terests. Currently, he is working on design optimiza-
2006. tion of a printed circuit heat exchanger using surro-
[11] Patankar, S. V., Numerical Heat Transfer and Fluid gate models.
Flow, pp. 113–137, Hemisphere, Washington, DC,
1980. Kwang-Yong Kim received his B.S. degree from
[12] Ferziger, J. H., and Peric, M., Computational Methods for Seoul National University in 1978, and his M.S. and
Ph.D. degrees from the Korea Advanced Institute of
Fluid Dynamics, Springer, Berlin, Germany, pp. 176–190,
Science and Technology (KAIST), Korea, in 1981
1980. and 1987, respectively. He is currently an Inha Fellow
[13] Menter, F. R., Two-Equation Eddy-Viscosity Turbulence Professor in the School of Mechanical Engineering
Models for Engineering Applications, AIAA Journal, vol. of Inha University, Incheon, Korea. Professor Kim is
32, no. 8, pp. 1598–1605, 1994. also the current editor-in-chief of the International
Journal of Fluid Machinery and Systems (IJFMS),
[14] Bardina, J. E., Huang, P. G., and Coakley, T., Turbu-
and the president of the Korean Fluid Machinery As-
lence Modeling Validation, 28th AIAA Fluid Dynamics sociation (KFMA). He is also a fellow of the American Society of Mechanical
Conference, Snow Village, CO, AIAA Paper 1997–2121, Engineers (ASME) and an associate fellow of the American Institute of Aero-
1997. nautics and Astronautics (AIAA).

heat transfer engineering vol. 35 no. 13 2014

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