PRESSURE DROP IN MULTI-PARALLEL CHANNELS OF CORRUGATED

PLATE STEAM CONDENSERS

Prabhakara Rao Bobbili1,* and Bengt Sunden2

1
Department of Mechanical and Chemical Engineering, School of Engineering and Physical Sciences,
Heriot-Watt University, Riccarton, Edinburg, EH14 4AS, UK; P.Bobbili@hw.ac.uk
2
Division of Heat Transfer, Department of Energy Sciences, Lund Institute of Technology, Lund
University, Box 118, SE-22100 Lund, Sweden; Bengt.Sunden@vok.lth.se

Abstract
An experimental investigation has been carried out to find the pressure difference of the process of
steam condensation across the port to channel in plate heat exchangers. In the present study, low
corrugation angle (30o) plates have been used for different number of channels, namely, 10 and 80. The
process steam entered at 1 bar with a small degree of superheat. Water has been used as the cold fluid. The
pressure probes are inserted through the plate gasket into both the inlet and exit ports of the channel. The
pressure drop of the process steam has been measured and recorded at the first, middle and last channels at
different flow and exit conditions for each plate package of the heat exchanger. Also, the overall pressure
drop has been measured at different conditions at the outlet of the process steam, i.e., full and partial
condensation. The pressure drop measurements have indicated that there is a considerable variation in
pressure drop from the first channel to the last channel due to flow maldistribution. The experimental data
has been analyzed to show how the flow maldistribution affects the pressure drop of a plate condenser.
1. Introduction
Plate heat exchangers (PHEs) have been widely used in food processing, chemical reaction processes
and many other industrial applications due to their high effectiveness, compactness, flexibility, and cost
competitiveness. Generally speaking, PHEs can serve as an alternative to shell-and-tube heat exchangers
for most applications at low and medium pressures. In recent times, plate heat exchangers have been also
widely used in application of two-phase processes, both condensation and evaporation (Wang et al., 1999a,
1999b, 2000, 2005). Note that PHEs are often called plate condensers when they are used for vapor
condensation. Some examples of industrial applications of vapor condensation were described by Wang
and Sunden (2003). However, the knowledge about their performance is very limited due to the relative
short experience. In order to further expand this application, work must be carried out to improve the
understanding and prediction of thermal and hydraulic performance for PHE condensers.
Condensation of vapors is one of the most important heat transfer processes. There are a limited number
of studies dealing with condensation of process fluids in plate heat exchangers. A few classical studies to
obtain the heat transfer data for condensation in plate heat exchangers are illustrated by Tovazhyanski and
Kapustenko (1984) for steam, Uehara and Nakaoka (1988) as well as Arman and Rabas (1995) for
ammonia and Kumar (1983) and Chopard et al. (1992) for refrigerants. A wide range of Reynolds number
and different corrugation angles ranging from 30 to 60o have been considered. In the shear-dominated
regime, the Akers (1959) method is recommended by Kumar (1983) for calculating the condensation heat
transfer coefficient. The single-phase flow relationships (for corrugated geometry) are then used to
calculate the heat transfer coefficient corresponding to the effective liquid mass flux. In the gravity-
controlled regime, Thonon and Chopard (1996) recommended the use of the Nusselt equation for a plain
surface. Therefore, in order to account for the effect of plate corrugations, the Nusselt number is multiplied
with an enhancement factor that is obtained from single-phase data (a ratio of heat transfer coefficients for
the corrugated surface to a plain surface at the same Re). Wang and Zhao (1993) have conducted an
analysis of the heat transfer and pressure drop for steam condensation and discussed the main factors
affecting the average condensation heat transfer coefficient in a plate condenser (PC). These are: total mass
velocity, steam content at the outlet of the PC, average condensation temperature difference, average
condensation pressure, and Prandtl number of the liquid. Thonon and Bontemps (2002) report results on
condensation of pure fluids and mixtures of hydrocarbons in a compact welded heat exchanger. Wang and
Sunden (2003) pointed out that the theoretical prediction of plate condensers is very difficult at this stage
and hence most of the investigators have concentrated on experimental investigations. However, most of
the literature available for two-phase flow plate condenser concerns prediction of the heat transfer
coefficient and friction factor on the two-phase side.
Previous work relating to two-phase flow in manifold has been dealt primarily with liquid-gas at each
junction. For two phase flow distribution in manifolds, authors like Seeger et al. (1986) and Lahey (1986)
have investigated two-phase (vapor and liquid) distribution in single T-junctions. Only a few studies on the
topic of two-phase distribution in manifolds have been presented. Nagata et al. (1988) conducted
experiments on a horizontal manifold with four vertical upward tubes. Recently, Bernoux et al. (2001)
experimentally studied the distribution of vapor and liquid phases at the inlet manifold of a compact heat
exchanger. Two-phase distribution in the channels are obtained by the use of mass flow rate and mass
quality measurements in each channel using transparent windows allowing the observation of two-phase
flow pattern of refrigerant 113 at different operating conditions. Vist and Pertersen, (2004) have conducted
an experimental investigation of two-phase flow distribution in compact heat exchanger manifolds
consisting of 10 round parallel tubes. Lee and Lee (2004) have examined the distribution of two-phase
annular flow at header-channels junctions for compact heat exchangers. They focused on the effect of the
intrusion depth of the channels to find an opportunity to achieve a uniform flow distribution of the liquid-
phase that may be useful in designing evaporators. Two-phase flow structures in compact heat exchangers
have been studied by Rong et al. (1995), Watanabe et al. (1995). Watanabe et al. (1995) investigated how
the heat load on the branches affected the two-phase distribution. However, none of these works studied the
actual pressure distribution in parallel channels of plate condensers/evaporators.
To observe the flow phenomena in the small and the large plate packages of plate heat exchangers, an
experimental investigation has been carried out to find the pressure difference of the process of steam
condensation across the port to channel in plate heat exchangers based on the previous theoretical and
experimental knowledge in plate heat exchanger technology, especially in the area of flow maldistribution
in plate packages (Bobbili et al. 2005, 2006a, 2006b, Rao et al. (2002) and Rao and Das (2004)).
2. Experimental Setup and Procedure
In order to investigate the distribution of the pressure of the port to channels and the process of steam
condensation in PHEs, a steam condenser test rig was set up The rig is designed specially for the process of
steam condensation in PHEs with the flexibility in choice of parameters such as steam and water flows,
water temperatures, outlet steam quality, inlet steam pressure, etc. The experimental tests were designed for
measuring the pressure distribution of the process steam condensation at different conditions, i.e., sub-
cooled (SC), fully saturated (FC) and partial steam condensation (PC). The test plate-and-frame heat
exchanger consists of a maximum of 81 (40/41) channels. It has been chosen to investigate the pressure
distribution during steam condensation in 10/11and 40/41 channels in a U-coupled plate package from the
first channel to the last channel as shown in Fig. 1. A schematic diagram of the test rig is shown in Fig. 2.
Steam was provided at about 12 bar and entered the separator (1), where water droplets were removed.
Steam pressure was set by means of a compressed air controlled pressure

Fig. 1 Various locations of the fixed pressure taps, the differential pressure transmitter and PT-100
thermometer across the tested plate heat exchanger.

Fig. 2 Schematic diagram of the test ring

 Fig.3(a): Geometric features of the plate

Fig. 4 Arrangement of the pressure taps of the channel in the tested plate heat exchanger.

reducing valve (2). The inlet steam flow was measured by Spirax Sarco Gilflo meter (3) with an accuracy
less than 1% of reading. The steam flow to the test object (5) was controlled by two manually operated
control valves (4) in parallel. The cooling water flow on the secondary side was measured by a Danfoss
electromagnetic meter (6) with inaccuracy less than 0.25% of the measured value. The outlet from the heat
exchanger was led to a separation vessel (7) incorporating a level gauge to view and determine when
stationary conditions were reached. Condensate flow rate was measured by a turbine flow meter (8)
manufactured by liquid control. For outlet steam flow rate measurement, a Spirox Sarco Votex VFM 2000
meter (11) was used. The condensate flow rate and outlet steam flow rate were controlled by manually
operated control valves, (9) and (10), respectively.
The specifications of the geometry of the used corrugated plate are given in Fig. 3. A magnetic flow
meter has been used to record mass flow rates of the cooling fluid (water). It has been calibrated with a
standard flow meter and the maximum deviation is about ±3.0%. Three differential pressure transmitters
are used to record the pressure drop across the channels (range 0-50 kPa), steam (0-32 kPa) and cooling
water (range 0-400 kPa). Two differential pressure transmitters are used to read the pressure drop across the
test plate heat exchanger at the inlet and outlet of the cold and hot fluid streams, which are connected to a
computerized data-acquisition unit and another pressure transmitter is used to measure the pressure drop
along the channels in the plate package by using small pressure steel tube taps having a 2 mm internal
diameter. The two small tubes were fixed to the corrugated plate by welding at the inlet and outlet of the
each channel port. The arrangement of the fixed pressure taps in relation to the particular channel is shown
in Fig. 4. The fixed pressure taps were connected using flexible pipes and these flexible pipes were fixed to
the pressure valve panel, where the inlet and outlet of the measured channel were connected to the pressure
transmitter as shown in Fig. 1. A multi-meter is used to record the pressure signal from the pressure
transmitter, which gives a signal in form of current (mA).
In addition to these, two mobile static pressure tubes were used to track the static pressure drop in both
the inlet and outlet ports at different locations of the channels. These were connected to a pressure valve
panel where the pressure transmitter is fixed, see Fig. 1. With these probes, the static pressure drop in each
channel can be measured. The deviation of the static pressure drops between the fixed probes and the
mobile probes at the particular location of the channel has been found to be about maximum ± 2.0 %. All
three pressure transmitters have been calibrated with a standard pressure meter and the maximum
uncertainty is about ±1.0%. Eight PT-100 thermometers were used to measure the inlet/outlet temperatures
of the cold and hot fluids in the plate heat exchanger as shown in Fig. 1. At each inlet and outlet of the fluid
steams, 2 PT-100 thermometers were fixed to record the average temperature of each fluid. These
thermometers were placed close to the PHE ports in the well-insulated pipe sections. All eight PT-100
thermometers were connected to the data-acquisition unit to record the fluid mean temperatures. These
thermometers were calibrated with a standard thermometer and the deviation from the standard
thermometer is about maximum ± 0.15%. The steam inlet pressure is around 1 bar. The experiments have
been carried out for three different conditions of steam condensation i.e., sub-cooling, saturated and partial
(50% dryness fraction of steam). These conditions were achieved by varying the inlet temperature of the
cooling fluid, Tc,in (water). All experimental data were recorded by a computerised data acquisition system.
All sensors and the data acquisition system were carefully calibrated together to get correct values in the
computer. In the tests, the heat balance between steam and cooling water sides is always within 10%. All
the test points were repeated several times for the same conditions to check the repeatability and consistent
results were found.

3. Results and discussion

The total steam flow rate at the inlet of plate heat exchanger was varied from 100 to 450 kg/hr. Water
was used as cooling fluid to condense the steam. The process steam entered at 1 bar with a small degree of
superheat. First, the heat balance was checked based on the heat flow rate on the steam side and the
cooling-water side, respectively. The variation is within 5%. In the present study, low corrugation angle
(30o) plates have been used for different number of channels, namely, 10 and 80. The number of channels
for steam condensation is always one less than the number of channels for water. The pressure probes are
inserted through the plate gasket into both the inlet and exit ports of the channel. The pressure drop of the
process steam has been measured and recorded at the first, middle and last channels for different flow and
exit conditions for each plate package of the heat exchanger (21 and 81 plates). Also, the overall pressure
drop has been measured at different conditions of the outlet of the process steam, i.e., sub-cooled, complete
and partial condensation. The quality of steam condensation has been calculated by measuring the mass
flow rate of steam at the inlet and outlet of PHE. Also, the quality of the steam by has been checked by an
enthalpy balance at the inlet and outlet conditions of the steam. The quality of steam (dryness fraction) is
defined as the ratio of the mass flow rate at the outlet over the inlet of steam.

Table 1: Conditions of steam condensation of 21 plate steam condenser.

Type of steam Gs Vc Tc,in

condensation kg/m2 s l/s o
C
Sub-cooled 34.68 2.85 60.61
condensation 53.01 2.84 60.41
(SC) 71.55 2.84 60.03
Full condensation 35.15 2.84 89.97
(FC) 51.35 2.66 85.03
85.95 2.81 73.72
Partial Condensation 52.37 2.84 90.25
(PC) 68.61 2.83 89.88
86.40 2.83 89.25
101.82 2.83 89.79
 Table 2: Conditions of steam condensation of 81 plate steam condenser.

Type of steam Gs Vc Tc,in

condensation kg/m2 s l/s o
C
Sub-cooled 87.36 3.23 65.50
condensation 122.60 3.22 52.76
(SC) 159.43 3.18 39.22
Full condensation 86.68 3.22 83.08
(FC) 121.59 3.22 70.95
Partial Condensation 86.97 3.22 93.58
(PC) 121.33 3.21 93.45
157.06 3.21 92.87

In steam applications of PHEs, the characteristics of the pressure drop are very important. The reasons
are as follows: (1) the condensation heat transfer and the pressure drop in PHEs are coupled to each other,
and therefore the characteristics of the pressure drop should be studied in order to predict the thermal
features. (2) PHEs are used only as a part of the steam system in practical applications. Control regulation
is related to the steam mass flow rate, the steam pressure, the internal condensate level and the coordination
with other facilities. This control depends mainly on the steam-side pressure drop. Hence, the investigation
of steam condensation pressure drop in PHEs becomes very important.
In the present study, the U type configuration has been chosen to analyse the pressure distribution due
to its practical importance. The overall pressure drop data between inlet and outlet of the plate heat
exchanger have been recorded at different steam flow rates and inlet temperatures of the cooling fluid,
water as shown in Tables 1 and 2. The mass flux is calculated based on the port cross-sectional area. Here,
the sub-cooled and partial condensation cases have been achieved by increasing the mass flow rates while
keeping constant cooling flow rate and inlet temperature. The overall/total pressure drop data includes the
two-phase frictional pressure drop, gravity pressure drop, acceleration pressure drop, and inlet and outlet
pressure drops of the connection and port. The recorded overall pressure drop data has been plotted against
the inlet steam mass flux (Gs) for different steam condensation at the outlet as shown in Figs. 5 and 6. In
Fig. 5, the overall pressure drop of 21 plate condenser is plotted, whereas Fig. 6 is for the 81 plates steam
condenser. The overall pressure drop of the process steam condensation increases with increasing total
steam flow rates. Also, one can observe that the overall pressure drop increases with increasing steam
dryness fraction at the outlet of the plate steam condenser. Therefore, the overall pressure drop of partial
steam condensation is higher than for the full/complete and sub-cooled condensation.

60 21 plate Steam Condensor

50
dp_SC
do_FC
40 dp_PC
∆ poverall, kPa

30

20

10

0
30 50 70 90
Gs, kg/m2 s

Fig. 5: The overall pressure drop of the process steam of 21 plate steam condenser at different steam
condensation.
 35
81 Plate Steam Condenser

dp_SC
25 dp_FC
∆ poverall, kPa

dp_PC

15

5
80 100 120 140 160

Gs, kg/m2 s

Fig. 6: The overall pressure drop of the process steam of 81 plate steam condenser for different steam
condensation cases.

60 dp_SC_ 21 Plates
dp_SC_ 81 Plates
dp_FC_ 21 Plates
50 dp_FC_ 81 Plates
dp_PC_ 21 Plates
dp_PC_ 81 Plates
40
∆ poverall, kPa

30

20

10

0
0 20 40 60 80 100 120 140 160
Gs, kg/m2 s

Fig. 7: Comparison of the overall pressure drop of the process steam of 21 and 81 plate steam condensers
for different steam condensation cases.

To find the effect of the number of channels/plates on different conditions for the process steam
condensation at a given total inlet mass flow rate, the overall pressure drops of 21 and 81 plate condensers
are compared in Fig. 7. The overall pressure drop of the81 plate condenser is smaller than that of the 21
plate condenser at the given total inlet steam flow rate as the net channel flow rate of large plate condenser
is smaller than that of the small plate condenser. Therefore, the overall pressure drop decreases by
increasing the number of plates.

dp_channel_SC; Gs = 34.68 kg/m2 s

dp_channel_SC; Gs = 53.01 kg/m2 s
dp_channel_SC; Gs = 71.55 kg/m2 s 21 Plate Steam Condenser
50 dp_channel_FC; Gs = 35.15 kg/m2 s
dp_channel_FC; Gs = 51.35 kg/m2 s
dp_channel_FC; Gs = 85.95 kg/m2 s
dp_channel_PC; Gs = 52.37 kg/m2 s
40 dp_channel_PC; Gs = 86.40 kg/m2 s
∆ pchannel, kPa

30

20

10

0
1 2 3 4 5 6 7 8 9 10
Channel number

Fig. 8: The channel pressure drop of the process steam for 21 plate steam condenser for different steam
condensation cases.

dp_channel_SC; Gs = 87.36 kg/m2 s

dp_channel_SC; Gs = 122.60 kg/m2 s
18 81 Plate Steam Condenser
dp_channel_SC; Gs = 159.43 kg/m2 s
dp_channel_FC; Gs = 86.68 kg/m2 s
dp_channel_FC; Gs = 121.59 kg/m2 s
dp_channel_PC; Gs = 86.97 kg/m2 s
dp_channel_PC; Gs = 157.06 kg/m2 s
13
∆ p channel, kPa

-2
0 5 10 15 20 25 30 35 40 45
Channel number

Fig. 9: The channel pressure drop of the process steam for 81 plate steam condenser for different steam
condensation cases.
 To observe the nature of the pressure profiles for steam condensation in the inlet and outlet of the ports
of plate steam condenser, the channel pressure drop of the first, middle and last channels were recorded for
sub-cooled, complete and partial steam condensation. Figure 8 shows the channel pressure drop of the
process steam of 21 plate steam condenser against the channel number. The channel pressure drop of the
first to last channels increases along with increasing the port length of the plate condenser for sub-cooled
and complete condensation. The situation is different for the partial condensation as the channel pressure
drop of the first to last channels decreases along with increasing the port length of plate condenser for sub-
cooled and complete condensation for the given conditions. These effects can be more clearly observed for
the 81 plate condenser as shown in Fig. 9.

dp_channel_SC; 21 Plates
dp_channel_FC; 21 Plates
dp_channel_PC; 21 Plates Gs = 86 kg/m2 s
50 dp_channel_SC; 81 Plates
dp_channel_FC; 81 Plates
dp_channel_PC; 81 Plates
∆ pChannel, kPa

30

First chanel Last Channel

Middle Channel
10

-10
0 5 10 15 20 25 30 35 40 45
Channel number

Fig. 10: Comparison of the channel pressure drop of the process steam for 21 and 81 plate steam
condensers for different steam condensation cases.

In order to find the effect of the number of channels on the pressure distribution of the process steam
condensation, the measured channel pressure drop data of 21 and 81 plate condensers are compared and
shown in Fig. 10. The first channel pressure drop is smaller than the last channel pressure drop for the
complete and sub-cooled steam condensation. However, the first channel pressure drop is higher than the
last channel pressure drop for partial steam condensation. Therefore, flow maldistribution has been
observed when the number channel increases.

4. Conclusions
An experimental study has been carried out to bring forward the effect of the number of channels on the
hydraulic performance of parallel channels of plate condensers (21 and 81 plate packages). An overall
pressure drop of the process steam has been measured at different exit steam condensation, i.e., sub-cooled,
complete and partial steam condensation for small and large plate packages. The obtained data for both
packages have been compared. The results show that the overall pressure drop of the partial steam
condensation is higher than that of the full/complete and sub-cooled steam condensation.
In order to reveal the effect of the number of channels on the pressure distribution of the process steam
condensation, the first, middle and last channel pressure drops of the process steam have been measured
and analyzed for different steam exit conditions. These results show that the first channel pressure drop is
smaller than the last channel pressure drop for the complete and sub-cooled steam condensation. However,
the first channel pressure drop is higher than the last channel pressure drop for the partial steam
condensation. Therefore, the flow maldistribution occurs when the number channel increases and the nature
of the pressure profiles are not the same at different steam exit conditions.

5. Acknowledgements

The authors gratefully acknowledge the financial support from the Swedish Research Council (VR) and
the Swedish Energy Agency (STEM). Alfa-Laval Lund is also acknowledged for co-operation and funding
the project.

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