Design and Production of a Novel Flat-Plate Heat Exchanger

Student: Victor Ukpono Ukpe (Project, 2025)
Department of Mechanical Engineering
University of Uyo, Akwa Ibom State

Abstract

This project presents the design, development, and testing of a novel flat plate heat exchanger (FPHE) aimed at addressing the limitations of conventional wavy-pattern designs, which typically exhibit moderate heat transfer efficiencies of 65% to 85%. The project’s main objective was to increase heat transfer efficiency to a target range of 90% to 95% while minimizing associated pressure drops, a common issue in enhanced heat exchanger geometries. A new plate pattern coined the "Half-Honeycomb" design, was conceptualized and optimized using Computational Fluid Dynamics (CFD) simulations in Autodesk CFD. Key materials including copper, high-carbon steel, and silicone rubber were selected based on thermal conductivity and structural integrity requirements. Comparative analysis between the new Half-Honeycomb pattern and the traditional Wavy pattern demonstrated a 62.9% improvement in heat transfer efficiency and a 1.21% reduction in pressure drop. These results suggest the potential for the new design to significantly enhance energy efficiency in industrial applications while maintaining operational costs. The use of 3D printing for prototype fabrication further illustrates the potential for cost-effective production, opening up new avenues for improving the performance of compact heat exchangers.

Keywords
flat-plate heat exchanger Half-Honeycomb heat transfer efficiency pressure drop CFD simulation 3D printing counterflow plate geometry prototype testing thermal performance
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