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INTRODUCTION
In many heat exchangers, the fluids are separated by a heat transfer surface,
and ideally they do not mix or leak. Such exchangers are referred to as direct transfer
type, or simply recuperate. In contrast, exchangers in which there is intermittent heat
exchange between the hot and cold fluids via thermal energy storage and release
through the exchanger surface or matrix are referred to as indirect transfer type, or
simply regenerators. Such exchangers usually have fluid leakage from one fluid
stream to the other, due to pressure differences and matrix rotation/valve switching.
Common examples of heat exchangers are shell-and tube exchangers, automobile
radiators, condensers, evaporators, air prehearters, and cooling towers.
1
1.2 Types of Heat Exchanger
2
1.3 Plate Heat Exchanger
Plate heat exchangers (PHEs) were introduced in the 1930s and were almost
exclusively used as liquid/liquid heat exchangers in the food industries because of
their ease of cleaning. Over the years, the development of the PHE has generally
continued towards larger capacity, as well as higher working temperature and
pressure. Recently, a gasket sealing was replaced by a brazed material, and each
thermal plate was formed with a series of corrugations (herringbone). These greatly
increased the pressure and the temperature capabilities.
The corrugated pattern on the thermal plate induces a highly turbulent fluid
flow. The high turbulence in the PHE leads to an enhanced heat transfer, to a low
fouling rate, and to a reduced heat transfer area. Therefore, PHEs can be used as
alternatives to shell-and-tube heat exchangers. R410A approximates an azeotropic
3
behaviour since it can be regarded as a pure substance because of the negligible
temperature gliding.
These geometric factors influence the separation, the boundary layer, and
the vortex or swirl flow generation. However, earlier experimental and numerical
works were restricted to a single-phase flow. Since the advent of a Brazed PHE
(BPHE) in the 1990s, studies of the condensation and/or evaporation heat transfer
have focused on their applications in refrigerating and air conditioning systems, but
only a few studies have been done. Much work is needed to understand the features of
the two-phase flow in the BPHEs with alternative refrigerants. Xiao yang
experimented with the two-phase flow distribution in stacked PHEs at both vertical
upward and downward flow orientations.
They indicated that non-uniform distributions were found and that the flow
distribution was strongly affected by the total inlet flow rate, the vapor quality, the
flow channel orientation, and the geometry of the inlet port Holger.
The main objective of this work was to experimentally investigate the heat
transfer coefficients and the pressure drops during condensation of R410A inside
BPHEs. Three BPHEs with different chevron angles of 45, 35, and 20 were used. The
results were then compared to those of R22. The geometric effects of the plate on the
heat transfer and the pressure drop were investigated by varying the mass flux, the
quality, and the condensation temperature.
The results, the geometric effects, especially the chevron angle, must be
considered to develop the correlations for the Nusselt number and the friction factor.
Correlations for the Nusselt number and the friction factor with the geometric
parameters are suggested in this study.
The results for the simplified model, presented in terms of velocity, shear stress
and heat transfer coefficients, strongly encourage the simulation of one channel of the
typical plate heat exchanger, i.e. the one that comprises of two corrugated plates with
herringbone design having their crests nearly in contact. Preliminary results of this
latter work, currently in progress, comply with visual observations.
In recent years, compact heat exchangers with corrugated plates are being
rapidly adopted by food and chemical process industries, replacing conventional shell-
and-tube exchangers. Compact heat exchangers consist of plates embossed with some
form of corrugated surface pattern, usually the herringbone geometry. The plates are
assembled being abutting, with their corrugations forming narrow passages. This type
of equipment offers high thermal effectiveness and close temperature approach, while
allowing ease of inspection and cleaning.
In order to be able to evaluate its performance, methods to predict the heat
transfer coefficient and pressure drop must be developed. In this direction, CFD is
5
considered an efficient tool for momentum and heat transfer rate estimation in this
type of heat exchangers.
The type of flow in such narrow passages, which is associated with the choice
of the most appropriate flow model for CFD simulation, is still an open issue in the
literature. Due to the relatively high pressure drop, compared to shell-and-tube heat
exchangers for equivalent flow rates, the Reynolds numbers used in this type of
equipment must be lower so as the resulting pressure drops would be generally
acceptable.
Moreover, when this equipment is used as a reflux condenser, the limit
imposed by the onset of flooding reduces the maximum Reynolds number to a value
less than 2000. In a comprehensive review article concerning modelling heat transfer
in narrow flow passages, state that, for the Reynolds number range of 1,500-3,000,
transitional flow is expected, a kind of flow among the most difficult to simulate by
conventional turbulence models.
They concluded that the flow patterns in such geometries are complex, due to
the existence of secondary swirling motions along the furrows of their test section and
suggest that the local flow structure controls the heat transfer process in such narrow
passages.
The most common two-equation turbulence model, based on the equations for
the turbulence energy k and its dissipation ε, is the k-ε model. To calculate the
boundary layer, either “wall functions” are used, overriding the calculation of k and ε
in the wall adjacent nodes, or integration is performed to the surface, using a “low
turbulent Reynolds (low-Re) k-ε” model. In standard k-ε the wall shear stress and heat
flux are over predicted (especially for the lower range of the Reynolds number
encountered in this kind of equipment) due to the over prediction of the turbulent
length scale in the flow reattachment region, which is a characteristic phenomenon
occurring on the corrugated surfaces in these geometries..
6
Moreover, when this equipment is used as a reflux condenser, the limit
imposed by the onset of flooding reduces the maximum Reynolds number to a value
less than 2000. In a comprehensive review article concerning modelling heat transfer
in narrow flow passages, state that, for the Reynolds number range of 1,500-3,000,
transitional flow is expected, a kind of flow among the most difficult to simulate by
conventional turbulence models.
They concluded that the flow patterns in such geometries are complex, due to
the existence of secondary swirling motions along the furrows of their test section and
suggest that the local flow structure controls the heat transfer process in such narrow
passages.
The most common two-equation turbulence model, based on the equations for
the turbulence energy k and its dissipation ε, is the k-ε model. To calculate the
boundary layer, either “wall functions” are used, overriding the calculation of k and ε
in the wall adjacent nodes, or integration is performed to the surface, using a “low
turbulent Reynolds (low-Re) k-ε” model. In standard k-ε the wall shear stress and heat
flux are over predicted (especially for the lower range of the Reynolds number
encountered in this kind of equipment) due to the over prediction of the turbulent
length scale in the flow reattachment region, which is a characteristic phenomenon
occurring on the corrugated surfaces in these geometries..
7
Figure 1.2 Gasket plate- and-frame heat exchanger
The resulting flow passages are narrow, highly interrupted, and tortuous, and
enhance the heat transfer rate and decrease fouling resistance by increasing the shear
stress, producing secondary flow, and increasing the level of turbulence. The
corrugations also improve the rigidity of the plates and form the desired plate spacing.
Plates are designated as hard or soft, depending on whether they generate a high or
low intensity of turbulence.
8
Figure 1.3 Gasket plates for plate heat exchanger
Each plate has four corner ports. In pairs, they provide access to the flow
passages on either side of the plate. When the plates are assembled, the corner ports
line up to form distribution headers for the two fluids. Inlet and outlet nozzles for the
fluids, provided in the end covers, line up with the ports in the plates (distribution
headers) and are connected to external piping carrying the two fluids. A fluid enters at
a corner of one end of the compressed stack of plates through the inlet nozzle.
9
It passes through alternate channels in either series or parallel passages. In one
set of channels, the gasket does not surround the inlet port between two plates. Fluid
enters through that port, flows between plates, and exits through a port at the other
end. On the same side of the plates, the other two ports are blocked by a gasket with a
double seal, so that the other fluid cannot enter the plate on that side.{ In a 1 pass–1
pass} two-fluid counterblow PHE, the next channel has gaskets covering the ports just
opposite the preceding plate. Incidentally, each plate has gaskets on only one side, and
they sit in grooves on the back side of the neigh boring plate, each fluid makes a
single pass through the exchanger because of alternate gasketed and ungasketed ports
in each corner opening.
Plates made from in coloy 825, Inconel 625, and Hastelloy C-276 is also
available. Nickel, cupronickel, and monel are rarely used. Carbon steel is not used,
due to low corrosion resistance for thin plates. Graphite and polymer plates are used
10
with corrosive fluids. The heat transfer surface area per unit volume for plate
exchangers ranges from 120 to 660m2/m3 (37 to 200 ft2/ft3).
Some advantages of plate heat exchangers are as follows. They can easily be
taken apart into their individual components for cleaning, inspection, and
maintenance. The heat transfer surface area can readily be changed or rearranged for a
different task or for anticipated changing loads, through the flexibility of plate size,
corrugation patterns, and pass arrangements. High shear rates and shear stresses,
secondary flow, high turbulence, and mixing due to plate corrugation patterns reduce
fouling to about 10 to 25% of that of a shell-and-tube exchanger, and enhance heat
transfer.
11
Very high heat transfer coefficients are achieved due to the breakup and
reattachment of boundary layers, swirl or vortex flow generation, and small hydraulic
diameter flow passages.
Also, the gross weight of a plate exchanger is about one sixth that of an
equivalent shell-and-tube exchanger. Leakage from one fluid to the other cannot take
place unless a plate develops a hole. Since the gasket is between the plates, any
leakage from the gaskets is to the outside of the exchanger. The residence time (time
to travel from the inlet to the outlet of the exchanger) for different fluid particles or
flow paths on a given side are approximately the same. This parity is desirable for
uniformity of heat treatment in applications such as sterilizing, pasteurizing, and
cooking.
There are no significant hot or cold spots in the exchanger that could lead to the
deterioration of heat-sensitive fluids. The volume of fluid held up in the exchanger is
small; this feature is important with expensive fluids, for faster transient response, and
for better process control. Finally, high thermal performance can be achieved in plate
exchangers. The high degree of counter flow in PHEs makes temperature approaches
of up to 18C (28F) possible.
The high thermal effectiveness (up to about 93%) facilitates economical low-
grade heat recovery. The flow-induced vibrations, noise, thermal stresses, and entry
impingement problems of shell-and-tube exchangers do not exist for plate heat
exchangers. Some inherent limitations of the plate heat exchangers are caused by
plates and gaskets as follows.
12
The plate exchanger is capable of handling up to a maximum pressure of about
3 MPa gauge (435 psig) but is usually operated below 1.0 MPa gauge (150 psig).The
gasket materials (except for the PTFE-coated type) restrict the use of PHEs in highly
corrosive applications; they also limit the maximum operating temperature to 2608C
(5008F) but are usually operated below 1508C (3008F) to avoid the use of expensive
gasket materials.
They are most common in the dairy, juice, beverage, alcoholic drink,
general food processing, and pharmaceutical industries, where their ease of cleaning
and the thermal control required for sterilization/pasteurization make them ideal. They
are also used in the synthetic rubber industry, paper mills, and in the process heaters,
coolers, and closed-circuit cooling systems of large petrochemical and power plants.
Here heat rejection to seawater or brackish water is common in many applications,
and titanium plates are then used.
13
Plate heat exchangers are not well suited for lower-density gas-to-gas
applications. They are used for condensation or evaporation of non-low-vapour
densities. Lower vapour densities limit evaporation to lower outlet vapour fractions.
14
CHAPTER II
LITERATURE REVIEW
A. BANI KANANEH et.al. [1] have proposed that Fouling inside gasketed
plate heat exchangers used in milk production has been reduced using nano-
composites coatings. An antifouling coating with low surface energy (low wettability)
led to a hydrophobic and oleophobic effect. Test facilities were constructed by the
Institute of New Materials (INM) and Institute of Environmental Process Engineering
(IUV), University of Bremen in Germany for the investigation of milk adhesion and
the stability of the coatings on rectangular plates and small cylindrical ducts. A
number of coatings and surface treatments were tested. Certain polyurethane-coated
plates and tubes formed thinner deposit layer compared to standard uncoated stainless
steel plates and tubes. The cleaning time for one coated tube was reduced by 80%
compared to the standard stainless steel one. A pilot plant including a milk pasteurizer
at LUFA Nord-West in Oldenburg-Germany was used for the thermal treatment of
whey protein solutions. Plates coated with different nano-composites as well as electro
polished plates were installed in the heating section of the pasteurizer. Significant
differences were observed between coated and uncoated plates. The coated plates
showed reduced deposit build up in comparison with the uncoated stainless steel
plates. Polyurethane-coated plates exhibited the thinnest deposit layer. Electro
polished plates also reduced deposit build up in comparison to the standard stainless
steel plates and were almost comparable to the coated plates. The time required for
cleaning in place (CIP) with the coated plates was reduced by 70% compared to
standard stainless steel plates.
HELENA F et.al. [3] have proposed that The continuous thermal processing
of liquid foods with a three-section plate heat exchanger (PHE), heat integration and a
non-isothermal holding tube was modelled in order to derive the temperature history
of the product and the lethality distribution. Linear temperature changes were assumed
along the process and plug-flow was considered with three options for residence time:
space time (bulk velocity), experimental mean residence time and minimum residence
time (theoretical or experimental). In order to validate and test the model, it was used
to simulate the operation of a laboratory-scale plate pasteurizer processing an enzymic
time-temperature integrator (TTI) at four temperature conditions (70, 75, 80 and 85
°C). Previous studies of residence time distribution and heat transfer in the equipment
provided important parameters for the simulation. Predicted results of temperature
distribution were in excellent agreement with experimental values and the simulated
process lethality was close to the value assessed with the TTI. A case study showed
the effect of the adopted residence time and the over-processing associated with a
non-isothermal holding tube with tubular connections
16
flow, resulting in temporary high values of the wall shear stress. Experiments were
conducted using a commercial stainless steel pilot scale plate heat exchanger (PHE)
with a calcium phosphate-rich whey protein solution as model fluid. The PHE system
was operated at a product side flow rate of 0.085 m3 h_1 (v = 0.1 m s_1, Re = 870)
heating the solution from 62 to 85 _C. The results show that the build-up of fouling
layers as well as the fouling layer composition was strongly dependent on the flow
conditions. The pulsation amplitude and mode mainly influenced the mineral
deposition and a reduction of fouling was achieved. Hence, the use of pulsed flow
provides an opportunity for the mitigation of milk fouling
PHAVANEE NARATARUKSA et.al. [5] have proposed that Fouling by
coconut milk at different heating temperatures (50e54.5 _C, 60e64.5 _C, and 70e74.5
_C) and at three volumetric flows (2,4 and 6 LPM) in a test section equipped with four
flat plates was studied. Measurement of the overall heat transfer coefficient (U) and
the compositions of deposit mass were completed in order to obtain fouling factors
(Rf) and an empirical model for the rate of increase or f Biot number (ΔBi/Δt) as a
function of the temperature (T) and the flow (F). The results illustrated that the fouling
factor increased, when the temperature fell due to a combination of chemical reaction
fouling from proteins and precipitation fouling from fat. The fouling factor also
increased, when the flow was lowered due to a slow rate of deposit removal
introduced by small shear force. Combination of the two effects revealed that the
effect of flow was less significant at higher temperatures. All results can be confirmed
by an analysis of fouling compositions. At high temperature conditions, more
denaturation of proteins resulted in less ability to entrap fat globules onto heating
surface. The heat resistance was found decreasing with increasing temperature
17
weight concentration of 0.25%, 0.35% and 0.8% as the working media. Baseonthe
experimental data ,nanofluid at all concentrations showed higher heat transferrate
(advantage) and pressure drop (disadvantage) than that of the distilled water, resulting
from higher thermal conductivity of the nanoparticle loaded in basefluid. In order to
evaluate the positive and negative aspects of the nanofluid applications in the PHE
simultaneously, parameter of performance index was introduced and the results
confirmed the potential of this type of nanofluid in PHE, by looking at the ratio of
convective heat transfer enhancement to the pressure drop
BEUF M et.al. [7] have proposed that Fouling of heat exchangers in dairy
industries is still quite a severe problem both technically and economically. Altering
the surface properties of the heating surfaces would be a way of solving this issue.
Modified steel surfaces were tested in an Alfa Laval V2 plate heat exchanger
throughout dairy product sterilization. The behavior was analyzed for 8 different
surface treatments, such as coatings (Diamond Like Carbon [DLC], Silica, SiOX, Ni
P-PTFE, Excalibur, Xylan) and ion implantation (SiF+, MoS2). All fouling and
cleaning experiments were carried out in standard and well-controlled operating
conditions. After fouling, no significant difference could be seen between all
the modified steels and the reference by statistical variance analysis. Cleaning
efficiency of Ni-PPTFE appeared significantly the best. It could be suggested that the
free surface energy plays a predominant role and the roughness a minor role in the
level of fouling and cleaning efficiency
19
surface modification on nucleation and crystal growth. Of particular importance is the
influence on the cleaning performance where the main potential can be expected.
Q. ZHAO et.al [10] have proposed that The adhesion of bacteria and proteins
on the surfaces of heat exchangers and food processing equipment has been
recognized as a widespread problem. Biofouling not only reduces heat transfer
performance significantly, but also causes considerable pressure drop, calling for
higher pumping requirements. Biofouling also present a considerable hygiene risk in
the food industry. It would be much more desirable if surfaces with an inherently
lower stickability for biofouling could be developed. In this paper, stainless steel 304
plates were modified by electroless plating Ni-P and small amounts of PTFE. The
experimental results showed that the surface free energy of the Ni–P–PTFE coatings,
which were altered by changing the PTFE content in the coatings, had a significant
influence on the adhesion of bacterial, protein and mineral deposits. The Ni–P–PTFE
coatings reduced the adhesion of these deposits significantly. The anti-fouling
mechanism of the composite coatings was explained with the extended DLVO theory.
S. LEE et.al [11] have proposed that Oxide nanofluids were produced and
their thermal conductivities were measured by a transient hot-wire method. The
experimental results show that these nanofluids, containing a small amount of
nanoparticles, have substantially higher thermal conductivities than the same liquids
without nanoparticles. Comparisons between experiments and the Hamilton and
Crosser model show that the model can predict the thermal conductivity of nanofluids
containing large agglomerated Al203 particles. However, the model appears to be
inadequate for nanofluids containing CuO particles. This suggests that not only
particle shape but size is considered to be dominant in enhancing the thermal
conductivity of nanofluids
20
K. S. HONG et.al [12] have proposed that Nanofluids have been attractive for
the last few years with the enormous potential to improve the efficiency of heat
transfer fluids. This work focuses on the effect of the clustering of nanoparticles on
the thermal conductivity of nanofluids. Large enhancement of the thermal
conductivity is observed in Fe nanofluids sonicated with high powered pulses. The
average size of the nanoclusters and thermal conductivity of sonicated nanofluids are
measured as time passes after the sonication stopped. It is found from the variations of
the nanocluster size and thermal conductivity that the reduction of the thermal
conductivity of nanofluids is directly related to the agglomeration of nanoparticles.
The thermal conductivity of Fe nanofluids increases nonlinearly as the volume
fraction of nanoparticles increases. The nonlinearity is attributed to the rapid
clustering of nanoparticles in condensed nanofluids. The thermal conductivities of Fe
nanofluids with the three lowest concentrations are fitted to a linear function. The Fe
nanofluids show a more rapid increase of the thermal conductivity than Cu nanofluids
as the volume fraction of the nanoparticles increases.
21
performances of the PHE. A 12-channelPHE with counter-current flows is used in
quantification of the milk deposition developed inside the channels. The
aggregationrate of unfolded protein is found to increase exponentially with increasing
wall temperature and is accompanied bya substantial reduction in the heat-transfer
coefficient.
A. BANI KANANEHA [15] have proposed that Fouling inside gasketed plate
heat exchangers used in milk production has been reduced using nano-composites
coatings. An antifouling coating with low surface energy (low wettability) led to a
hydrophobic and oleophobic effect. Test facilities were constructed by the Institute of
New Materials (INM) and Institute of Environmental Process Engineering (IUV),
University of Bremen in Germany for the investigation of milk adhesion and the
stability of the coatings on rectangular plates and small cylindrical ducts. A number of
coatings and surface treatments were tested. Certain polyurethane-coated plates and
tubes formed thinner deposit layer compared to standard uncoated stainless steel
plates and tubes. The cleaning time for one coated tube was reduced by 80%
compared to the standard stainless steel one. A pilot plant including a milk pasteurizer
at LUFA Nord-West in Oldenburg-Germany was used for the thermal treatment of
whey protein solutions. Plates coated with different nano-composites as well as
electropolished plates were installed in the heating section of the pasteurizer.
Significant differences were observed between coated and uncoated plates. The coated
plates showed reduced deposit buildup in comparison with the uncoated stainless steel
plates. Polyurethane-coated plates exhibited the thinnest deposit layer. Electro
polished plates also reduced deposit buildup in comparison to the standard stainless
steel plates and were almost comparable to the coated plates. The time required for
cleaning in place (CIP) with the coated plates was reduced by 70% compared to
standard stainless steel plates.
BYEONG-JU JINA et.al. [16] have proposed that Generally, the heat transfer
performance of plate-type heat exchanger has been shown lower than other heat
exchangers.Recently titanium material that has high formability and performance has
been payed attention to a plate material of the plate-type heat exchange. However, the
material has a spring-back due to the high strength as well as the mold design for die
22
and punch processes determined by the operator’s experience. Furthermore, the
factors that affect the sheet forming are too large and complex to describe by
mathematical method so that it is quite difficult for the exact design by experimental
methods. Since the chevron shape and pattern are important factors in the performance
of the plate-type heat exchanger, the heat exchanger that has the same performance
with the targeted one has been manufactured in conjunction with mold design. This
design has been employed to predict and determine performance of plate-type heat
exchanger. If the mold design of the plate-type heat exchanger has considered to the
spring-back phenomenon, the design of twodimensional shape should necessarily be
required. Therefore, the compatibility and adequacy of mold design in the platetype
heat exchanger which is used in the industries, can be verified using three-dimensional
(3D) Finite Element Method(FEM). In this paper, a forming analysis of a plate-type
heat exchanger with its numerical simulation has been carried out. The optimization of
mold design in plate-type heat exchanger that has the complex shape has been
proposed using the computer simulation. Since the high-tensile steel plate such as Ti
material has high stability when designing a metal mold in the new product, an
optimization in the quality of plate-type heat exchanger using the developed numerical
model has been proposed.
VÁCLAV DVORAKA et.al. [17] have proposed that Flow and heat transfer
in a recuperative counter flow plate air-to-air heat exchanger were investigated
numerically using Fluent software. It was employed previously developed methods to
generate a computational mesh and assumed a zero thickness of the plates to calculate
the flow in an air-to-air heat exchanger. Pressure loss and effectiveness were
evaluated as functions of inner velocity. Obtained numerical data were substituted by
suggested functions dependent on the Reynolds number. A function for the loss
coefficient was based on the presumption that losses consist of local losses and
friction losses. The function for the Nusselt number used the ordinary power function
of the Reynolds number for forced convection. The effect of material thickness on
pressure loss and effectiveness was illustrated. Even a very thin material for the plate
significantly affects pressure loss, while the effect on the effectiveness depended on
the thermal conductivity of plate material used. From this results, it is obvious that a
23
thin as possible material is crucial for creating the most effective recuperative air-to-
air heat exchanger with high effectiveness and low pressure loss, while the properties
of the material itself are unimportant. We compared numerical data with data obtained
by measuring a real heat exchanger. The results for effectiveness corresponded well
and corrections made were negligible. Then results for pressure loss differed
significantly, but this difference was lowered by correcting for plate thickness.
NUR ROHMAH et.al. [18] have proposed that spacing is one of variable that
influences plate heat exchanger (PHE) design as a condenser in Organic Rankine
Cycle (ORC) system. The rises of plate spacing have effects to channel cross sectional
area, channel velocity, equivalent diameter, and Reynold number at hot and cold fluid
sides in PHE. Those parameters affect the total heat transfer area and total pressure
drop that influence the PHE condenser performance. This paper investigated the detail
effect of the plate spacing increments in the final total heat transfer area and total
pressure drop design result. The plate spacing in design calculation method is varied
and the other independent variables are assumed to be constant. The design was
conducted by calculating condenser capacity at both sides and both zones, estimating
overall heat transfer coefficient, and calculating heat transfer area and plate film
coefficient. Analysis continued by calculating overall heat transfer coefficient that has
small percent of error with the estimated overall heat transfer coefficient, calculating
pressure drop, total plate number and total heat transfer area. The result of calculation
shows that the rises of plate spacing increase the total heat transfer area and decrease
the cold and hot fluid total pressure drop. The rises of plate spacing increase channel
cross sectional area and equivalent diameter, and decrease channel velocity and
Reynold number at zone 1 (without phase change) and zone 2 (with phase change).
Therefore, the increment of heat transfer areas is unpreferable and the decrement of
pressure drops is preferable
OANA GIURGIU et.al. [19] have proposed that The study presents a
Computational Fluid Dynamics (CFD) numerical study for two different models of
mini channels, included in plate heat exchangers structure. The influence of geometric
characteristics of the two studied plates on the intensification process of heat transfer
was studied comparatively. For this purpose, it was examined the distribution of
24
velocity, temperatures fields and distribution of convection coefficient along the
active mini channel. The analyzed mini channels had the inclination angles of 30°
respectively 60° and the Reynold flow number was 3500. Also a session of
experimental measurements have been carried out on the two types of analyzed plates
for the heat exchangers, confirming the results obtained through numerical simulation
that the plate heat exchanger model using mini channels with inclination angle of β =
60ᵒ provides best heat transfer
25
CHAPTER III
PROBLEM IDENTIFICATION
Delplace et al., 1994 Gasketed plate heat exchangers with stainless steel
plates are commonly used in the dairy industry. They have high heat transfer
Performance, lower temperature gradient, higher turbulence, and easier
maintenance than shell and tube heat exchangers
The aim of the present study is HTST method will be attain to increase
the temperature in pasteurization process with short time duration using
nanofluids
26
CHAPTER IV
METHODOLOGY
Fabrication of PHE
Preparation of nanofluid
Observation
Various observations
for different flow adjustment
Conclusion
27
CHAPTER V
EXPERIMENTAL SETUP
The plate heat exchanger is formed up by a set of corrugated metal plates. The
corrugated plates are mounted in a frame with a fixed plate on one side and a movable
pressure plate and pressed together with tightening bolts. The corrugated plates serve
not only to raise the level of turbulence, but also provide numerous supporting points
to withstand the pressure difference between the media.
The hot medium may not flow through the apparatus without the cold medium
flowing through. This is to prevent damage to the apparatus. In case the cold medium
is present but does not flow while the hot medium is flowing through, the cold
medium will start boiling and the apparatus will be damaged.
Frames
Pressure Plates
Gaskets
Flow Arrangements
Thermocouple
U-Tube manometer
Rota meter
Gate valve
Hot and cold fluid tank
Connecting tubes
28
5.1.1.1 Frame
The plate package consists of plates with a groove along the rim of the plate
and around the ports. The number of plates is, as well as size and dimension,
dependent on the thermal output required. Depending on the application stainless-steel
or titanium plates might be used.
The heat exchanger plates, which make up the heat transfer surface, are
clamped between two plates of steel with the use of the tightening bolts. The heat
exchanger construction allows a plate heat exchanger to be easily opened for
inspection and cleaning.
The plate pattern is corrugated and varies depending on the application and the
fluids being put through the heat exchanger. As the plate’s corrugation depth gets
smaller the thickness of the plate can be less.
29
Each heat exchanger plate is formed by pressing in one piece (no seams or
welds).
Most plates have four holes punched, one in each corner. The last plate in a
single pass unit has no holes so the fluid flow is reversed or turned.
Multiple pass heat exchangers have turning plates with only two holes for
redirecting the fluid flow.
5.1.1.3 Gaskets
Each plate has a gasket that produces a sealing and channel system through the
entire plate pack in which the two heat exchanging media flow in a counter-current
direction.
The circular portion of the gasket stops the fluid from going across the heat
transfer plate and sends it to the next open channel. The remaining portion or field
gasket directs the opposing fluid across the heat transfer surface.
The gasket can be mechanically clipped to the plate with the glue free “U”
shaped clip or glued in place. The gasket is double around the ports toprevent
30
intermixing of the two fluids. In the event of gasket failure, any leakage is vented
external to the equipment.
They limit the maximum operating temperature for a plate heat exchanger.
Material selection depends upon
Chemical resistance
Temperature resistance
Sealing properties
Shape over an acceptable period of time
The heat transfer plates with gaskets are arranged in an alternating pattern of
left hand flow and right hand flow to direct the fluids in an opposing direction within
the heat exchanger. The completed assembly of all the plates and gaskets is called the
“plate pack.”
“A” “B”
The starter plate against the fixed cover does not have fluid flowing across it.
Instead it has four ring shaped gaskets to seal against the inside of the connections. In
31
this manner, fluids do not flow between this plate and the fixed head and are diverted
to open channels in the plate pack.
The groove provided in the plates holds the special gasket. The purpose of this
gasket is to prevent intermixing of the media and leakage to the outside. The gaskets
are selected to suit the actual combination of temperature, chemical environment and
possible other conditions to be considered. They can be supplied in Viton, Nitrile or
EPDM.
5.1.1.5Thermocouple
A thermocouple is an electrical device consisting of two dissimilar electrical
conductors forming electrical junction at differing temperature. A thermocouple
produce a temperature-dependent voltage as a result of thermoelectrical effect and this
voltage can be interpreted to measure the temperature. Thermocouple are widely used
type of temperature sensor.
5.1.1.7 Rotameter
Gate valve are primarily used to permit or prevent the flow of liquid, but
typical gate valve shouldn’t be used for regulating flow.
32
5.2 Apparatus
1. A stainless steel plate heat exchanger with a facility to measure inlet and
outlet temperature of hot and cold fluid with an accuracy of 0.1˚ C.
2. The plates are planar (not corrugated), There are a total of 5 plates
making 4 chambers for the fluid transport–two for the cold fluid and two
for the hot fluid.The total heat transfer area available is equal to that of
the number of plates
3. The cold fluid used here is water and the hot fluid is also water.
4. A stainless steel insulated tank with a heater to act as a reservoir for the
hot fluid.
5. Hot fluid circulation pump is used as 1HP power output and which is
have head displacement upto 20m.
6. Cold fluid inlet from the pump which is having 28W output and which
having head displacement upto 5m.
7. Four temperature sensors at the inlet and outlet points for each of the
two fluids. The hot-fluid inlet wired thermocouple is also a thermostat
control, which controls the heater connected to the reservoir by a simple
relay mechanism.
33
5.2.1 Schematic Diagram of Experimental Setup
34
5.3 General Setup
2. Set the temperature of the inlet hot fluid in the dual temperature indicator
cum controller. The set point should be set around 65 to 70˚C.
3. Provide cooling water supply to the plate heat exchanger so that the flowrate
is 111kg/h. This will ensure that the temperature rise is restricted to about 2–3˚C.
Keep this flow rate constant throughout the experiment.
4. Connect the 15 A and 5 A plug pins to a stable 230 V A.C. electric supply.
Care should be taken to connect these two pins in different phases of the power
supply. Switch on the heater power supply.
5. Adjust the flow rate of hot fluid through the heat exchanger by adjusting the
speed of hot fluid circulation pump. Note down the flow rate of hot fluid as indicated
by the rotameter. If during the course of any experiment, the flow rate changes (due to
power fluctuations, or due to temperature changes), to manually reset the flow rate to
the desired set value. This kind of adjustments should be done for all the experiments
to follow to ensure that the flow rate is maintained at a constant value.
35
5.4 Selection of Material
LMTD : 35.99 K
No. of Frames :1
5.5 Features
High heating transferring coefficient: as the flowing made in the plate pack
forms up turbulence at low Re and the smooth plates have little possibility of
forming scale, the plate heat exchanger has a heat transferring coefficient over
5000W/m2k, which is 2-4 times that of the shell-and-tube exchanger.
High heat recovery rate: Due to high heat-transferring coefficient, the heat
transferring temperature difference can be very low. Therefore, it is very well
suited to low energy level heat recovery. Normally heat recovery using a plate
heat exchanger can be as high as 90%.
Great flexibility
Compact structure
Easy maintenance.
36
CHAPTER VI
NANOFLUID
6.1 Nanofluid
Oxide ceramic
Al2O3
CuO
SiO2
Metal carbides
SiC
37
Metal
Al
Cu
Non-metal
Graphite
Carbon Nano Tube
Because heat transfer takes place at the surface of the particle, it is desirable to
use a particle with a large surface area. Nanoparticles provide extremely high surface
areas for heat transfer and therefore have great potential for use in heat transfer. The
much larger relative surface areas of nanophase powders, when compared with those
of conventional micrometer-sized powders, should markedly improve the heat transfer
capabilities and stability of the suspensions.
38
6.4.3 Minimal Clogging
39
6.5.2 Two –step method
40
6.6 Nanofluids Preparing Techniques
Magnetic Stirrer
Ultrasonic Bath Sonicator
Magnetic stirrers are often used in chemistry and biology, where they can
be used inside hermetically closed vessels or systems, without the need for
complicated rotary seals. They are preferred over gear-driven motorized stirrers
because they are quieter, more efficient, and have no moving external parts to
break or wear out (other than the simple bar magnet itself).
Magnetic stir bars work well in glass vessels commonly used for
chemical reactions, as glass does not appreciably affect a magnetic field. The
limited size of the bar means that magnetic stirrers can only be used for
relatively small experiments, of 4 liters or less.
Stir bars also have difficulty in dealing with viscous liquids or thick
suspensions. For larger volumes or more viscous liquids, some sort of
mechanical stirring is typically needed. Because of its small size, a stirring bar
is more easily cleaned and sterilized than other stirring devices. They do not
require lubricants which could contaminate the reaction vessel and the product.
41
Magnetic stirrers may also include a hot plate or some other means for heating
the liquid.
42
ultrasonic foil can distribute cellulose fibres more uniformly and strengthen the
paper.
These bubbles act like miniature high speed brushes, driving the
liquid into all openings and minutes recesses of the Object immersed
in the liquid.
Intense scrubbing of Cavitation cleans away all the dirt and soil from
the object immersed and the object is perfectly cleaned.
43
6.7. PREPARATION OF NANOFLUIDS
The preparation of nanofluid must ensure proper dispersion of
nanoparticles in the liquid and proper mechanism is needed to attain the stability
of the suspension against sedimentation.
The pH value of the base fluid is adjusted with the addition of small
amount of hydrochloric acid or sodium hydroxide.
It is a simple techniques and the cost is lower than the one step method. In
this method, firstly the nanoparticles are made in dry powdered by means of a
44
physical and chemical process, these nanoparticles are dispersed in base fluids
by using magnetic stirring and ultrasonication.
During this process, they are many bubbles appeared at the surface of
suspension nanoparticles after stirring process.
It can adhere the bubbles in a beaker wall. Due to high surface activity, the
stirring process is easily helps to dissolve the air in the fluids and easily the
bubbles were formed.
For this problem, the reduction in the stirring speed from 1200 r/min to 800
r/min and the stirring speed is extended upto 40 min.
By this method, the formation of bubbles were reduced effectively and the
obtained nanofluids quality is improved. After the stirring process, the beaker is
placed in a ultra sonication process.
During this process, the sonication temperature is various from 40ᴼC to 60ᴼC
for same concentration. Then make sample for a respected temperature degrees.
Nanoparticles tend to aggregate with the time elapsed for its high surface-
activity. The agglomeration of nanoparticles results not only the settlement and
clogging of micro channels but also the decreasing of thermal conductivity of
nanofluids. So the investigation on stability is also a key issue that influenced the
properties of nano fluids .The most important factors affecting the stability of
suspensions were the nanoparticles concentration, dispersant, viscosity of base liquid
and pH value. The stability of nanofluids also depends on the type of the
nanoparticles, size and shape of the nanoparticles and the intensity of ultrasonic
vibration used. Hwang studied the stability of nanofluids with the UV–vis
spectrophotometer.
i. Sedimentation method
Magnetic fluids (Ferromagnetic fluid) are kinds of special nanofluids. They are
stable colloidal suspensions of small magnetic particles such as magnetite (Fe3O4).
The properties of the magnetic nanoparticles, the magnetic component of magnetic
46
nanofluids, may be tailored by varying their size and adapting their surface coating in
order to meet the requirements of colloidal stability of magnetic nanofluids with non-
polar and polar carrier liquids . Comparing with the mechanical sealing, magnetic
sealing offers a cost-effective solution to environmental and hazardous-gas sealing in
a wide variety of industrial rotation equipment with high speed capability, low friction
power losses and long life and high reliability. Ferro-cobalt magnetic fluid was used
for oil sealing, and the holding pressure is 25 times as high as that of a conventional
magnetite sealing
6.9.4 Transportation
47
.For the US electric power industry, using nanofluids in closed loop cooling cycles
could save about 10–30 trillion year (equivalent to the annual energy consumption of
about 50,000–150,000 households).
Due to the restriction of space, energy, and weight in space station and aircraft,
there is a strong demand for high efficient cooling system with smaller size. Further
research of nanofluids will lead to the development of next generation of cooling
devices that incorporate nanofluids for ultrahigh-heat-flux electronic systems,
presenting the possibility of raising chip power in electronic components or
simplifying cooling requirements for space applications..
48
6.9.8 Solar Absorption
Solar energy is one of the best sources of renewable energy with minimal
environmental impact. The conventional direct absorption solar collector is a well
established technology, and it has been proposed for a variety of applications such as
water heating; however the efficiency of these collectors is limited by the absorption
properties of the working fluid, which is very poor for typical fluids used in solar
collectors. Recently this technology has been combined with the emerging
technologies of nanofluids and liquid-Nanoparticle suspensions to create a new class
of Nanofluid-based solar collectors. reported the experimental results on solar
collectors based on nanofluids made from a variety of nanoparticles (CNTs, graphite,
and silver)
49
6.10 Characterization
50
6.10.2 Transmission Electron Microscopy (TEM)
It is a tool used for identifying the atomic and molecular structure of a crystal,
in which the crystalline atoms cause a beam of incident X-rays to diffract into many
specific directions. By measuring the angles and intensities of these diffracted beams,
a crystallographer can produce a three-dimensional picture of the density
of electrons within the crystal. From this electron density, the mean positions of the
atoms in the crystal can be determined, as well as their chemical bonds,
their disorder and various other information
It is measuring the size of particles typically in the sub micron region, also
referred to as Photon Correlation Spectroscopy or Quasi-Elastic Light Scattering
particles suspended within a liquid undergo Brownian motion. The larger the particle,
the slower the Brownian motion will be. DLS monitors the Brownian motion with
light scattering.
51
6.11 Thermal Properties of Nanofluid
6.11.1 Introduction
Thermal fluids provide a situation for changing the energy of system cat
transfer efficiency of these fluids depends on their physical properties such thermal
conductivity, viscosity, density and specific heat. Due to low thermal conductivity of
traditional thermal fluid like water, ethylene glycol, and oils centrists try to find a new
coolant with higher thermal capacity. Nanofluid is a pension of solid particles in size
of nanometer in base fluid to increase its thermal capacity. Before appearance of
nanofuid were used micro or millimetre size particles Thermal conductivity is more
important in nanofluid. In fact it's enhancement than traditional fluid, is the benefit a
of nanofluids. Duo to thermal conductivity play a key role in laminar fluid flow than
turbulent one most researches focus on stationary state or very low velocity of
nanofluids now. In using suspensions we must pay special attention on particle
motions.
6.11.3 Viscosity
52
6.11.4 Density
The materials density is defined as their m per unit volume. Density very
important role in heat transfer especially in natural convection. Base of inverse effect
on natural convection.
Specific heat capacity which known simply as specific heat, is the measure of
the heat energy required to increase the temperature of a unit quantity of a substance
by a certain temperature interval. It is another thermo physical property which is
important as well as other ones. Nobody can deny its effect on Prandtl number, heat
capacity per unit mass and in general heat transfer.
53
CHAPTER VII
The milk pasteurization is one of the food preservation methods using thermal
treatment. The purpose of pasteurization is to extend the life period of the product.
In pasteurization process, first the raw milk is heated about certain At this
temperature the microorganisms or microbe temperature bacteria's or pathogens
present in the milk is destroyed. This is called as heat treatment
Then the pasteurized milk is cooled by using the heat transferring devices like
heat exchangers. Now the temperature of the pasteurized milk equal to or slightly
above the atmospheric temperature.
The above said treatment is very useful to increase the life period of the
product. There are no of methods are used in food preservation techniques. There are
no of treatments, methods and purposes of pasteurization are given below.
These temperatures are equivalent and are sufficient to destroy the most heat
sensitive of the non-spore-forming pathogenic organisms. Milk pasteurization
54
temperatures are also sufficient to destroy all yeasts, moulds, gram negative bacteria
and many gram positive. The two groups of micro- organisms that survive
pasteurisation temperatures used in milk are:
72 15 sec HTST
55
7.4 Methods for Pasteurizing
There are number of basic methods of pasteurization widely used in the industry.
In this method every particle (e.g. milk) must be heated to at least 63°C and held for at
least 30 minutes, however this is not used commercially these days.
In this method the heating of every particle of milk to at least 72°C and
holding for at least 15 seconds. Carried out as a continuous process. Ultra Heat be
performed using higher temperatures and shorter times e g. 1 s at 135oC
Some liquid foods (e.g. beer and fruit juices are pasteurized after filling
containers. Hot water is normally used if the food is packaged into glass, to at reduce
the risk of breakage due to thermal shock. Maximum temperature between the
container and the liquid are 20°c for heating and 10°c cooling. or Metal and plastic
containers may be pasteurized using steam-air mixtures or hot water. Pasteurisers ma
be batch or continuous. A simple batch type may be a water bath in which s stes of the
food are heated to a pre-set temperature, and then cooled by draining and adding cold
water.
56
A continuous version may convey containers through a hot water batch
followed by a cold water bath. Steam tunnels may also be used with the advantage of
faster heating, resulting in shorter residence time and smaller equipment.
Temperatures in the heating zones may be controlled depending on the amount of air
present. Acid products such as fruit or acidified vegetables like beetroot can be
pasteurized in a retort. lone 3 Lone zone l Preheating Presenting Pasturing Cooling
57
CHAPTER VIII
W nanoparticle
ρ nanoparticles
∅= × 100
W nanoparticles W water
+
ρ nanoparticles ρ water
Where,
𝜌𝑓 = Density of nanofluid
𝜌𝑝 = Density of nanoparticles
∅ = Volume concentration
∅ × {𝜌𝑝 × 𝑐𝑝𝑝 }
[ ]
+(1 − ∅) × {𝜌𝑓 × 𝑐𝑝𝑝 }
𝑐𝑝,𝑛𝑎𝑛𝑜𝑓𝑙𝑢𝑖𝑑 =
𝜌𝑛𝑓
58
Where,
Where,
Where,
59
8.1.7 Over All Heat Transfer Co-Efficient
U= [1/hi+1/ho]-1
Q = UA ΔTm
Size = 50nm
60
8.5 Observations for Water as A Coolant
S.No Hot Fluid Cold Fluid Cold In Cold Out Hot In Hot Out
(Tci) (Tco) (Thi) (Tho)
LPH LPH ºC ºC ºC ºC
1. 60 60 30 51 70 61
2. 70 70 30 54 70 59
3. 80 80 30 57 70 53
S.No Hot Fluid Cold Fluid Cold In Cold Out Hot In Hot Out
(Tci) (Tco) (Thi) (Tho)
LPM LPM ºC ºC ºC ºC
1. 60 60 30 53 70 57
2. 70 70 30 57 70 54
3. 80 80 30 60 70 50
61
8.7 Calculation
Cpnf= ɸCpp+(1-ɸ)Cpf
=1.94893 kj/kg.k
Mh=ρh x vh
Q=2161.107 W
=(70-57)-(63-30)/ ln{70-57)/(63-30)}
ΔTm =16.84ºc
Q= UAΔTm
U=154.67 w/mº c
62
CHAPTER IX
Actual experimentation on corrugated plate heat exchanger has been carried out
as per integrated research methodology. The results of heat transfer rate and overall
heat transfer coefficient for counter flow arrangement with the different mass flow
rate are presented
1.9495
1.949
1.9485
specific heat kj/kg.k
1.948
1.9475
specific heat (kj/kg.k)
1.947
1.9465
1.946
1.9455
0.1 0.15 0.2 0.25 0.3
concentration %
63
Chart 9.2. shows the differens of concentration with respect thermal
conductivity. Increase in concentration results into increase in thermal conductivity of
fluid.
0.6364
0.6362
Thermal conductivity w/m.k
0.636
0.6358
0.6356
0.6354
0.6352 thermal conductivity
0.635 (w/m.k)
0.6348
0.6346
0.6344
0.6342
0 0.1 0.2 0.3 0.4
concentration %
Chart 9.3. shows the differens of concentration with respect heat transfer rate.
Increase in concentration results into increase in heat transfer rate of fluid.
21.35
21.3
21.25
Heat transfer rate kw
21.2
21.15
21.1
21.05
21 heat transfer rate kw
20.95
20.9
20.85
20.8
0 0.1 0.2 0.3 0.4
concentration %
64
Chart 9.4. shows the differens of concentration with respect overall heat
transfer coefficient. Increase in concentration results into increase in overall heat
transfer rate of fluid.
overall heat transfer coefficient
92
91
90
w/m2k
89
overall heat transfer co
88 efficient (W/m2k)
87
86
85
0 0.1 0.2 0.3 0.4
concentration %
For the nano fluid based heat transfer different results are based of different
parameter such as heat transfer rate, over all heat transfer coefficient, mass flow rate,
specific rate, thermal conductivity.
Increasing the heat transfer coefficient indicate the flow in more turbulent. Its
results obtaining heat transfer rate and lower fowling.
The above said result clearly indicates that the heat transfer rate and overall
heat transfer coefficient is higher by using nano fluid as a cold fluid compared to
water as a cold fluid
65
S.No. Concentration SPECIFIC THERMAL HEAT OVERALL
HEAT CONDECTIVITY TRANFER HEAT
(%)
(kj/kg.k) (w/m.k) RATE TRANSFER
COEFFICIENT
(kw)
(w/m2k)
Chart 9.5 show with the concentration with specific heat, thermal conductivity,
heat transfer rate, overall heat transfer coefficient while increase the concentration the
performance will be increased
100
overall performance evaluation
60
thermal conductivity
40 (w/m.k)
heat transfer rate kw
20
overall heat transfer
0
co efficient (W/m2k)
0 0.1 0.2 0.3 0.4
concentration %
t
66
CHAPTER X
The main focus of using nanofluid, it has high thermal conductivity than base
fluid like water, ethylene glycol, etc nanofluid will be prepare by using nanoparticles
and the base fluid such as demineralized water. The flow rate will be adjusted. Then
the various set of temperature will be analyzed. From this work we expected that the
enhancement of high heat transfer rate. To get efficient heat transfer rate counter flow
arrangements are made in this work.
By using the above work conclude that can apply the plate heat exchanger
setup in various heat transfer application for different fluid in various heat transfer
application for different fluid for various industries. The plate heat exchanger having
three or more times more than heat transfer coefficient then shell and tube heat
exchanger. This approaches is suitable and simple tool for use in the determine of
overall heat transfer coefficient and heat transfer rate
Nanofluid can be used as a more efficient working fluid in PHE rather than
mostly .Its performance depends upon the surface area concentration and flow rate of
nanofluid. Enhancement of approximately 46% heat transfer rate observed with the
mixing of nanofluid concentration
As with the use of nanofluids results shows better heat transfer so it can compel
to use smaller plate heat exchanger to achieve the same results, which can effectively
not only reduce our capital cost but also the maintenance cost
This work is further extended to analyse the heat transfer rate and reduction of
fouling using nanoparticles coating on the plate heat exchanger
67
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68
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on Heat Exchanger Fouling and Cleaning.
14. Youcef Mahdi , Abdelkader Mouheb , Lounes Oufer (2009) A dynamic model
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16. Byeong-Ju Jin, Jong-Pyo Leea, Min-Ho Parka, Tae-Jong Yuna, Youg-Ho
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70
WEBSITES:
http://www.apv.com/us/products/heatexchangers/heat+exchangers.asp
http://www.plateheatexchangersindia.com/F19492/gasketed_plate_heat_
exchangers.html
http://www.alfalaval.com/products-and-solutions/plate-heat-
bexchangers/Pages/Plate-heat-exchangers.aspx
http://www.engineersedge.com/heat_exchanger/plate.htm
http://www.brazetek.com/3-x-8-inch-34-inch-mpt-connections-stainless-
steel-copper-brazed-plate-heat-exchangers-chillers
71
PHOTOGRAPH
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