Numerical Investigation and Analysis on Thermal-Hydraulic Characteristics of an Elliptical Embossment Plate Heat Exchanger

Abstract

Dimpled and embossed surfaces are widely used to enhance the performance of plate heat exchangers (PHEs). In this work, the thermal–hydraulic behavior of a PHE with a newly proposed elliptical embossment pattern was examined through numerical simulation. The study focused on two key geometric parameters—embossment depth and pitch—and their influence on heat transfer and flow resistance. Three‑dimensional simulations were carried out in ANSYS Fluent using the realizable k–ε turbulence model with enhanced wall functions, covering Reynolds numbers from approximately 100 to 2000. The results indicate that both the Nusselt number (Nu) and the thermal–hydraulic performance factor (F) rise with increasing embossment depth and pitch, while the friction factor (f) shows a decreasing trend under the same conditions. These findings suggest that careful tuning of the elliptical profile can achieve a favorable balance between heat transfer enhancement and pressure drop, offering practical guidance for the design of next‑generation high‑efficiency PHEs.