Thermal-hydraulic performance of printed circuit heat exchangers: CFD analysis with experimental validation

Results of a computational fluid dynamic (CFD) study of flow and heat transfer in a printed circuit heat exchanger (PCHE) geometry are presented. CFD results obtained from a two-plate model are compared to corresponding experimental results for the validation. This process provides the basis for further application of the CFD code to PCHE design and performance analysis in a variety of internal flow geometries. As a part of the code verification and validation (V & V) process, CFD simulation of a single semicircular straight channel under laminar isothermal conditions was also performed and compared to theoretical results. This comparison yielded good agreement with the theoretical values. The two-plate CFD model based on the experimental PCHE design overestimated the effectiveness and underestimated the pressure drop. However, it is found that the discrepancy between the CFD result and experimental data was a result of the uncertainty in the geometry of heat exchanger during the fabrication. The CFD results obtained using a slightly smaller channel diameter yielded good agreement with the experimental data. A separate investigation revealed that the average channel diameter of the OSU PCHE after the diffusion-bonding was 1.93 mm on the cold fluid side and 1.90 mm on the hot fluid side which are both smaller than the nominal design value. Consequently, the CFD code was shown to have sufficient capability to evaluate the heat exchanger thermal-hydraulic performance.