Computational Analysis of Plate Heat Exchangers Corrugation Alignment on the Thermo-hydraulic Performance under Different Phase Shift Angles

Enhancing the thermo-hydraulic performance of compact heat exchangers remains a critical challenge for improving energy efficiency and reducing operational costs. In this study, a numerical analysis investigation was conducted to evaluate the effects of corrugation phase shift angles (ϕ) on flow structure, heat transfer behavior, and pressure drop characteristics in corrugated plate heat exchanger. Four phase shift angles (0°, 15°, 30°, and 45°) were investigated within the range of Reynolds numbers of 200–1000. It is found that there exists a reduction in heat transfer efficiency with increasing phase shift angles. The wavy channel configuration with ϕ = 0ᵒ at Reynolds number 1000 showed respectively 3.82, 1.15, 1.26, and 1.37 times higher than those of the straight channels, wavy channels with ϕ = 15ᵒ, 30ᵒ, and 45ᵒ. In addition, an increase in phase shifts results in a reduction of the Fanning friction factor, indicating a reduction in pressure drops attributed to smoother flow and weaker vortex excitation near the channel crests. This behaviour demonstrates a clear thermo-hydraulic trade-off between heat transfer enhancement and flow resistance. The performance evaluation criterion (PEC) values for ϕ= 0°, 15°, 30°, and 45° were 2.55, 2.31, 2.05, and 2.01, respectively. Likewise, increasing the phase angle reduces the pressure drop, resulting in a reduction in the cost of pumping power.