Numerical Simulation of a Brazed Plate Heat Exchanger using Al2O3-
Water Nanofluid with Periodic Boundary Conditions
MADHU KALYAN REDDY PULAGAM, SACHINDRA KUMAR ROUT,
SUNIL KUMAR SARANGI
Department of Mechanical Engineering
C. V. Raman Global University,
Bidyanagar, Mahura, Bhubaneswar, Odisha-752054
INDIA
Abstract: - Brazed plate heat exchangers are used as evaporators, condensers, and single-phase heat exchangers
in the industry. This complex piece of engineering has the effectiveness and compactness to give it an edge
over many conventional heat exchangers. Solar power plants and organic Rankine cycle systems do use these
heat exchangers as a part of heat recovery systems. The complex channels formed by the angled sinusoidal
plates allow the fluid to be in a turbulent zone at a low Reynolds number, thus promoting better heat transfer
characteristics. The challenge of simulating these heat exchangers is the large computational requirements. This
can be solved by using periodic boundary conditions where a single repeating element is simulated to analyze
the heat transfer characteristics of the entire channel. Varying concentrations of Al2O3 Nanofluid were
considered as the working fluid for this study. The variation in the concentration did not affect the Nusselt
number showing that the heat transfer coefficient was completely dependent on the hydraulic diameter and the
thermal conductivity of the fluid. The friction factor also did not change with varying concentrations but the
pressure drop increased as the chevron angle, pitch, and concentration increased.
Key-Words: - Brazed Plate, Heat Exchangers, Periodic boundary condition, CFD, friction factor, Nusselt
number, HVAC.
Received: May 22, 2023. Revised: October 19, 2023. Accepted: December 11, 2023. Published: December 31, 2023.
1 Introduction
Brazed plate heat exchangers are made up of plates
with sinusoidal corrugations stamped at an angle.
These plates are stacked over one another in such a
way that a channel forms in between the plates. The
contact points of the two plates along with the edges
are then brazed. This results in a complex zig-zag,
rising and falling channels for the fluid to flow as
shown in Figure 1. This promotes heat transfer to a
much better degree than a flat plate heat exchanger.
Many studies over the years have used different
fluids for a variety of applications. Some studies
included the use of refrigerants such as [1], and
some have used water, [2]. While most of the
studies were experimental, some CFD-based studies
also gained prominence in analyzing the heat
transfer characteristics of these heat exchangers.
The present article focuses on the use of periodic
boundary conditions, which allow the simulations to
be performed at a faster rate and provide accurate
results.
Fig. 1: Schematic of the plate arrangement and flow
pattern
2 Literature Review and Objectives
CFD simulations to study the brazed plate heat
exchangers alongside experimental work, [3]. The
same heat exchanger was simulated with different
turbulent models and determined that the turbulence
model did not make a significant impact on the
results, [4]. A plate heat exchanger with sinusoidal
corrugations at low Reynolds numbers, [5],
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Madhu Kalyan Reddy Pulagam,
Sachindra Kumar Rout, Sunil Kumar Sarangi
E-ISSN: 2224-3461
262
Volume 18, 2023
simulated. The fluid was highly viscous and the
resistances offered by the fluid increased with an
increase in chevron angle. A plug flow was
simulated in one dimension for a 4-channel plate
heat exchanger, [6]. The k-ε turbulence model with
enhanced wall treatment was used. Another work
included simulation of small-sized PHE using the k-
ε realizable model with non-equilibrium wall
conditions, [7]. Milk as a working fluid was
simulated to study the fouling and flow patterns of
the plate heat exchangers used in the milk
processing industry, [8] and [9] used the k-ω model
and experimental analysis to observe the effect of
chevron angles on the performance characteristics of
BPHE.
Nanofluids were used in a couple of studies related
to brazed plate heat exchangers. The heat transfer
and pressure drop characteristics of one such
nanofluid (TiO2-water nanofluid) in a Brazed plate
heat exchanger, [10] were investigated. Previous
studies have published that the Nusselt number
increased with the increase in the Reynolds number
and volume fraction of the nanoparticles.
characteristics of carbon-based nanofluids in BPHE
under laminar flow, [11], was also studied. Two
different concentrations were selected (0.2% wt. and
0.6% wt.) and their thermophysical properties such
as thermal conductivity, and viscosity, were
measured, analyzed and then the nanofluid was
circulated inside a brazed plate heat exchanger to
evaluate the average heat exchange capacity,
pumping power consumption and system efficiency
factor with inlet temperatures of 35, 40, and 45°C
under laminar flow conditions. The system
efficiency factor was slightly higher for lower
concentration nanofluid than the higher one (7.98%
as opposed to 7.28%) and considering all the
properties and parameters the lower concentration
nanofluid was recommended by the authors. the heat
transfer and flow characteristics of a Multi-walled
carbon nanotube - copper oxide (MWCNT-CuO)
nanofluid in BPHE, [12], were studied and
optimized. The nanofluid was compared with water
as a cold fluid and was run through a test heat
exchanger. An increase of 39.27% was calculated in
the thermal conductivity. The friction factor
increased slightly when compared with water. The
same fluid, [13], was also studied for the thermal
performance and flow analysis. A Nusselt number
increase of 94% and a friction factor increase of
12.87% from the base fluid was reported. Energy
consumption of H-type (larger chevron angle) and
L-type (smaller chevron angle) brazed plate heat
exchangers, [14], were compared and reported. The
experiments were carried out at different flow rates
of water. The H-type had better heat transfer as well
as pressure drop at all flow rates but was more
pronounced at higher flow rates.
3 Materials and Methods
Most of the CFD-based studies done have simplified
the geometry in one way or another, [8], but some of
them have simulated the entire geometry, [4]. These
studies were done at the expense of high
computational resources that an ordinary student
might not have in possession. A close look at the
geometry of the channel or the plates itself can
reveal a pattern that repeats periodically. The end
effects are not very significant since most of the
heat transfer already happened in between the
corrugations. Periodic boundary condition is an
option in ANSYS Fluent which would simulate the
effect of repeating patterns. This was taken as the
key research methodology for this study. The
repeated section length and width are modeled and
simulated with constant heat flux conditions. A
sinusoidal curve was created and extruded at an
angle to create a plate. The same was done with an
offset above the starting point of the original curve
and rotated it to form the second plate. The region
inside them was filled and the solid plates were
deleted to retain the fluid medium. The remaining
model was trimmed down to the periodic length and
width. The geometry and periodic section are given
in Figure 2. Simulations were designed for variation
of pitch, amplitude-to-pitch ratio, chevron angle,
and Reynolds number. Meshing was done in ICEM
CFD since the default meshing module could create
negative volume meshes. Using a block method in
the ICEM CFD module it was easier to map out the
mesh and then project it onto the curved surfaces to
create a hexahedral structured mesh as shown in
Figure 3. The grid independence test was done to
identify the ideal number of elements and the sizing
conditions used to create that mesh were considered
for the remaining models. Laminar and standard k-ω
SST models were used for the viscous models and
the k-ω SST model was declared to be more suitable
for computing a brazed plate heat exchanger, [4].
The convergence criteria were considered as 10-6 for
all the residuals. A coupled discretization scheme
was used with turbulence, energy, and pressure
solvers at second-order discretization. The working
fluid was taken as water with a constant heat flux
condition given on the top and bottom walls. A
sample model was simulated for grid independence
and width independence test to check for the ideal
mesh and dependence of width for the periodic
conditions on the left and right walls. The results are
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Madhu Kalyan Reddy Pulagam,
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E-ISSN: 2224-3461
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as given in Figure 4. The ideal mesh elements are
around 3 x 106 elements since a 5% better result at
higher angles is available at almost 2 - 2.5 times the
selected size which increases the computation time
drastically.
Fig. 2: Periodic model geometry
Fig. 3: Meshing of the model
The equations that were solved in the
background are given in Eq. 1 – 11. The standard k-
ω model is a two-equation model solved for
turbulent flows, and the equations are given in Eq. 4
and 5. The SST version of this model accounts for
the transport of the turbulence shear stress in the
definition of turbulence viscosity as given in Eq. 6.
The velocity in periodic flow is calculated as given
in Eq. 7, 8, and 9, [15]. The pressure drop and
temperature between the periodic faces are periodic
and are calculated as given in Eq. 10 and 11, [15].
Fig. 4: Grid independence test
Continuity Equation
(1)
Momentum Equation
(2)
Energy Equation
(3)
(4)
(5)
(6)
(7)
(8)
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(9)
(10)
(11)
(12)
;
;
(13)
The temperature and pressure drop data from
Fluent are analyzed using Eq. 10 & 11 to get the
friction factor and Nusselt numbers. Some sample
cases were simulated to validate the results of the
friction factor against the existing correlations, [14],
as shown in Figure 5. The results fairly agreed with
the calculated friction factor from the existing
correlations except with low Re for Nu. The
correlation underpredicted the value mainly due to
the lack of consideration for the enlargement factor
that results in a higher surface area for the plate heat
exchanger.
The more accurate simulation of nanofluids
should be using a multi-phase model. Due to the
restrictions of the periodic boundary conditions
without using a UDF, multi-phase flow is not
possible. Thus, the properties of the nanofluid with
Al2O3 particle size of 25 nm have been derived
using a correlation from [16] and [17]. These
properties are input as new fluids in ANSYS Fluent
and then simulated to get more acceptable rather
than accurate values. This is a small price to pay
when looking at the huge computational
requirements of simulating a 4 million-element full
plate model. The fluid properties are given in Table
1.
.
Fig. 5: Validation against experimental correlations
given in [18]
Table 1. Al2O3 – water nanofluid properties
S.
N
o
Volu
me
fracti
on
Densi
ty
(kg/m
3)
Dyna
mic
viscosi
ty
(Pa-s)
Thermal
conductiv
ity
(W/m-K)
Specif
ic
heat
(J/kg-
K)
1
0.5%
1009.
17
0.0007
99
0.622
4119.
51
2
0.75%
1015.
93
0.0008
04
0.633
4089.
87
3
1%
1022.
69
0.0008
29
0.641
4060.
62
4 Results and Discussion
The fluids are simulated through 5 different chevron
angles (15 to 75) of three different heat
exchangers with pitches of 4 mm, 6 mm, and 8 mm
and amplitude to pitch ratio of 0.2. the node data of
each model is extracted and fed into a program that
separates the values into each block of 100 equal
blocks across the model. The bulk and surface
temperature were averaged over each block and the
entire block at the end to calculate the heat transfer
coefficient and Nusselt number. The pressure drop
values are a direct output of the periodic boundary
10 100 1000 10000
0.01
0.1
1
10
f
Re
Numerical Data, b = 300
Numerical Data, b = 450
Numerical Data, b = 600
Kumar et al., b = 300
Kumar et al., b = 450
Kumar et al., b = 300
110 100 1000 10000
5
50
500
10
100
Nu
Re
Numerical Data, b = 300
Numerical Data, b = 450
Numerical Data, b = 600
Kumar et al., b = 300
Kumar et al., b = 450
Kumar et al., b = 600
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Volume 18, 2023
conditions, which are used to calculate the friction
factor. As expected, the friction factor did not
change its value with an increase in concentration.
However, the value decreased with increasing Re
and increased with increasing pitch and angle.
Compared to plain water the friction factor was
similar for the nanofluid and so was the pressure
drop. The pressure drop was only slightly higher
(less than 1% for the highest values) so the friction
factor changes were also of a similar magnitude.
Figure 6 shows the variation of friction factor and
pressure drop for various chevron angles. It was also
found that the friction factor increases 6 to 8 times
from the lowest Re to the highest Re for the smallest
angle of 115 degrees and the highest angle of 75.
It was also observed that there was a maximum of
20% increase in friction factor as the pitch was
increased and this was also mostly insignificant
considering the absolute magnitude of the friction
factor as shown in Figure 7.
Fig. 6: f vs Re and Pressure drop per unit length vs
Re for various β
10 100 1000 10000
0.01
0.1
1
f
Re
water
0.5 % Al2O3
0.75 % Al2O3
1 % Al2O3
b = 15o
10 100 1000 10000
1
10
f
Re
water
0.5 % Al2O3
0.75 % Al2O3
1 % Al2O3
b = 75o
10 100 1000 10000
0.01
0.1
1
10
100
DP/L (kPa/m)
Re
water
0.5 % Al2O3
0.75 % Al2O3
1 % Al2O3
b = 15o
10 100 1000 10000
0.01
0.1
1
10
100
1000
DP/L (kPa/m)
Re
water
0.5 % Al2O3
0.75 % Al2O3
1 % Al2O3
b = 45o
10 100 1000 10000
0.001
0.01
0.1
1
10
100
1000
10000 b = 75o
DP/L (kPa/m)
Re
water
0.5 % Al2O3
0.75 % Al2O3
1 % Al2O3
10 100 1000 10000
0.1
1
f
Re
water
0.5 % Al2O3
0.75 % Al2O3
1 % Al2O3
b = 45o
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Fig. 7: f vs Re for various pitches of the corrugation
The effect of the different nanofluids was
similar for the Nusselt number too. The values
overlapped almost in all cases as shown in Figure 8.
The increase in the Nu with Re was anywhere
between 25 – 50 times depending on the chevron
angle and the Reynolds number. At low Reynolds
numbers, the Nusselt numbers were very similar to
each other for all values of pitch and chevron angle.
All the different concentrations have very similar
Nu throughout with a maximum difference of 6%.
Increasing the pitch had a similar effect on the
Nusselt number where it was barely different for
almost all Re as shown in Figure 9. [17], did give a
different result to what was published in this article.
The Nusselt number was the least for the distilled
water and the maximum for the nanofluid with a 2%
volume fraction. The major difference is the
application where this nanofluid was used. It was
used in a simulation of a shell and tube heat
exchanger where the nanofluid was on the tube side
with a uniform cross-section. The brazed plate heat
exchanger is a completely different scenario. This
shows that the Al2O3 nanofluid concentration under
1% does not make much of a difference in the
pressure drop or the heat transfer coefficient. So, for
economic reasons, it is better to use normal water.
10 100 1000 10000
10
100
Nu
Re
water
0.5 % Al2O3
0.75 % Al2O3
1 % Al2O3
b = 15o
10 100 1000 10000
10
100
Nu
Re
water
0.5 % Al2O3
0.75 % Al2O3
1 % Al2O3
b = 45o
10 100 1000 10000
10
100
b = 75o
Nu
Re
water
0.5 % Al2O3
0.75 % Al2O3
1 % Al2O3
10 100 1000 10000
10000
h
Re
water
0.5 % Al2O3
0.75 % Al2O3
1 % Al2O3
b = 15o
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Fig. 8: Nu vs Re and heat transfer coefficient vs Re
for various β
Fig. 9: Nu vs Re for various pitches of the
corrugation
5 Conclusions
The Al2O3 nanofluid was used in the simulation of a
braze plate heat exchanger for different chevron
angles and pitches and the results were compared
with water. The fluid properties were introduced
into the fluent as a new homogeneous fluid and the
simulations were carried out. Periodic boundary
conditions were used to reduce the computational
time and resources by decreasing the number of
elements to 0.3 million when previous studies used
models over 2 million elements.
The friction factor increases 6 to 8 times from
the lowest Re to the highest Re for the smallest
angle of 15° and the highest angle of 75°. It was
also observed that there was a maximum of 20%
increase in friction factor as the pitch was
increased.
The Nusselt number slightly increased by about
2% from normal water for the nanofluid. All the
different concentrations have very similar Nu
throughout with a maximum increase of 6%
from a lower to higher concentration.
The brazed plate heat exchanger combined with
nanofluids can work in areas requiring high heat
load with small spaces such as Organic Rankine
cycle systems. These systems generally require
transfer at high heat loads in a limited space.
Shell and tube or tube-in-tube heat exchangers
cannot function as well as a brazed plate heat
exchanger with its compactness and heat
transfer properties.
Acknowledgement:
This work has been supported by the Board of
Research in Nuclear Science (BRNS) under grant
No. 59/14/03/2021-BRNS/57032. The authors are
also grateful to Dr. Debakant Samal, Institute of
Physics, Bhubaneswar, for our Principal
collaborator for his continuous academic and
technical support.
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1000
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Volume 18, 2023
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Madhu Kalyan Reddy Pulagam,
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E-ISSN: 2224-3461
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Volume 18, 2023
NOMENCLATURE
Cross-sectional area
[m2]
Surface area
[m2]
Hydraulic diameter
[mm]
Heat transfer
Coefficient
[W/m2-
K]
Friction factor
--
Turbulence kinetic
energy
[J]
Thermal conductivity
[W/m-
K]
Length
[m]
Periodic length
[m]
Mass flow rate
[kg/s]
Nusselt Number
--
Pressure
[Pa]
Pitch
[m]
Pressure gradient
[Pa/m]
Heat flux
[W/m2]
Position vector
--
Reynolds number
--
Source term
--
Strain magnitude
--
Time
[s]
Temperature
[K]
Bulk Temperature
[K]
Surface Temperature
[K]
Velocity field in x
direction
[m/s]
Velocity field in y
direction
[m/s]
Velocity field
[m/s]
Velocity field in z-
direction
[m/s]
Average velocity
[m/s]
Dissipation term due to
turbulence
--
Distance to the next
surface
[m/s]
Density
[kg/m3]
Area enlargement factor
--
Effective diffusivity
[m2/s]
Specific dissipation rate
[m2/s3]
Coefficient of damp
turbulent viscosity
--
ɸ
Fin height (H) to width
(s) ratio
--
Viscosity
[Pa-s]
Contribution of Individual Authors to the
Creation of a Scientific Article (Ghostwriting
Policy)
- Madhu Kalyan Reddy Pulagam,: simulation and
experimental test rig set up,
- Sachindra Kumar Rout: Manuscript preparation
and result analysis
- Sunil Kumar Sarangi: Idea generation and draft
correction
Sources of Funding for Research Presented in a
Scientific Article or Scientific Article Itself
This work has been supported by the Board of
Research in Nuclear Science (BRNS) under grant
No. 59/14/03/2021-BRNS/57032. The authors are
also grateful to Dr. Debakant Samal, Institute of
Physics, Bhubaneswar, for our Principal
collaborator for his continuous academic and
technical support.
Conflict of Interest
The authors have no conflicts of interest to declare.
Creative Commons Attribution License 4.0
(Attribution 4.0 International, CC BY 4.0)
This article is published under the terms of the
Creative Commons Attribution License 4.0
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_US
WSEAS TRANSACTIONS on HEAT and MASS TRANSFER
DOI: 10.37394/232012.2023.18.22
Madhu Kalyan Reddy Pulagam,
Sachindra Kumar Rout, Sunil Kumar Sarangi
E-ISSN: 2224-3461
270
Volume 18, 2023
