International Journal of Thermal Sciences 109 (2016) 263e269

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International Journal of Thermal Sciences

journal homepage: www.elsevier.com/locate/ijts

Experimental analysis of a mixed-plate gasketed plate heat exchanger

and artificial neural net estimations of the performance as an
alternative to classical correlations
Caner Turk, Selin Aradag*, Sadık Kakac
TOBB University of Economics and Technology, Department of Mechanical Engineering, Sogutozu Cad. No: 43, 06560, Ankara, Turkey

a r t i c l e i n f o a b s t r a c t

Article history: In this study, experiments are performed to test the thermal and hydraulic performance of gasketed plate
Received 18 February 2016 heat exchangers (GPHE). A heat exchanger composed of two different plate types is used for the ex-
Received in revised form periments, for a Reynolds number range of 500e5000. The results are compared to the experimental
6 June 2016
results obtained for plate heat exchangers which are composed of plates that have the same geometry
Accepted 6 June 2016
instead of mixing two different plates. Two methods are used to investigate the thermal and hydraulic
Available online 15 June 2016
characteristics based on the obtained experimental data. One of them is the classical correlation
development for Nusselt number and friction factors. Artificial neural networks (ANNs) are also used to
Keywords:
Artificial neural network
estimate the performance as an alternative to correlations. Different networks with various numbers of
Gasketed plate heat exchanger hidden neurons and layers are used to find the best configuration for predictions. The results show that,
Correlation artificial neural networks can be an alternative to experimental correlations for predicting thermal and
Nusselt number hydraulic characteristics of plate heat exchangers. They give better performance when compared to
Friction factor correlations which are very common in heat transfer applications. Especially for mixed plate configu-
Experiment rations studied in this research, where different plate types are used as a combination in the complete
heat exchanger, it is difficult to obtain a single correlation that represents all the plates in the heat
exchanger. However, when ANN’s are used, it is easier to predict the performance of mixed plate HEX and
the predictions are more reliable when compared to correlations.
© 2016 Elsevier Masson SAS. All rights reserved.

1. Introduction
Heat exchangers are used to transfer heat or/and mass between
two or more streams at different temperatures. For saving energy
and resources, it is important to increase the thermal performance
of heat exchangers. One way is to make the exchanger more com-
plex with extended surface area. Gasketed plate heat exchanger is
one of the complex heat exchanger types. The complexity of these
systems is due to their geometry which allows higher thermal
performance by increasing the heat transfer area. Design of heat
exchangers is performed by obtaining certain important parame-
ters such as Nusselt number and friction factor. These values are
calculated using experimentally obtained correlations which
involve errors. Therefore, alternative methods are utilized for per-
formance prediction of heat exchangers and other heat transfer
* Corresponding author.
E-mail addresses: selinaradag@gmail.com, saradag@etu.edu.tr (S. Aradag).
devices.
In literature, there are several studies on heat exchangers and
artificial neural network methodology. Xie et al. [1] used ANN’s to
estimate oil outlet temperature, water outlet temperature and heat
transfer rate in a shell and tube heat exchanger. In the same work,
the disadvantage of using correlations to describe heat exchanger
performance is pointed out. They explained that if correlations are
used to predict heat transfer rates, iterations are necessary; how-
ever when ANN’s are used, there is no need for iterations. Pacheco-
Vega et al. [2] examined the ANN method in fin-tube refrigerating
heat exchangers and stated that the magnitude of errors between
ANN method and the experiments are more or less the same as the
uncertainties in the measurement devices. Islamoglu [3] investi-
gated the usage of ANN’s for wire-on-tube type heat exchangers.
The results showed that ANN method gives better results for the
prediction of heat transfer rate when compared to correlations.
Peng et al. [4] studied genetic algorithms combined with back
propagation neural networks for the optimal design of plate-fin
heat exchangers (PFHE). The aim of this work was to find an

http://dx.doi.org/10.1016/j.ijthermalsci.2016.06.016
1290-0729/© 2016 Elsevier Masson SAS. All rights reserved.
264 C. Turk et al. / International Journal of Thermal Sciences 109 (2016) 263e269

In this work, first, experiments are performed to test the per-

Nomenclature formance of gasketed plate heat exchanger configurations. Then,
correlations are developed to represent the thermal and hydraulic
ANN GPHE Artificial Neural Network Gasketed Plate Heat performances. This work also shows the usage of Artificial Neural
Exchanger Networks (ANNs) to obtain more accurate results compared to
Er Relative Error correlations for Nusselt number and friction factor of gasketed plate
rms Root-mean-square heat exchangers, especially for heat exchangers for which different
Nu Nusselt Number types of plates are used as a combination.
f Friction factor
R Evaluation factor for average accuracy
2. Methodology
s Evaluation factor for scatter accuracy
corr Correlation
2.1. Geometrical properties of the tested plates
exp Experiment
PFHE Plate Fin Heat Exchanger
The plate heat exchanger that is tested has 20 plates. 10 of them
have a chevron angle of 27.5
and 10 of them have a chevron angle
of 62.5
. The plates are arranged consequtively, one with a smaller
optimal design of PFHE for minimum total weight and total annual angle followed by one with a larger chevron angle. The geometrical
cost for given constrained conditions. This study was the first parameters for the tested plates are measured using Laser Stereo-
successful application of genetic algorithms (GA) combined with lithography and the data is used to generate the three dimensional
back propagation neural networks and the method was accepted as solid model of the plates. The solid models of the plates are shown
universal. Peng et al. [5] estimated pressure drop and heat transfer in Fig. 1. The plate properties are summarized in Table 1.
characteristics using ANN’s in PFHE’s. First, thermal performances The heat transfer areas used in heat transfer calculations must
of five different PFHE’s were obtained experimentally. Then, the include both the areas of the distribution channels and the area
results of the experiments were used to train ANN’s. Training inside the channels. However, the area of the distribution channels
continued until an acceptable level of accuracy was achieved. After is very small; therefore it is neglected in the calculations.
the network was obtained, tested data was supplied as inputs then
the results were compared with the ones obtained from experi- 2.2. Experimental methodology
ments. Colburn factor (j) and friction factor (f) were predicted using
ANN’s. All error values were in the range of 0%e5%. As a result of the The experiments are performed at TOBB ETU Plate Heat Ex-
study, it was observed that ANN models could be used to predict changers Laboratory in order to determine the thermal and hy-
the performances of thermal systems. Islamoglu et al. [6] studied draulic performances of plate heat exchangers composed of two
on a non-adiabatic capillary tube suction line heat exchanger and different plates. The test set-up used in the experiments, is shown
used an ANN model to predict suction line outlet temperature and in Fig. 2. The details of the set-up are given in the studies of
mass flow rate. Several ANN models were investigated for trained Gulenoglu et al. [11] and Akturk et al. [12].
data and the model with the lowest absolute mean relative error U-type, counter flow, single pass system is used with water as
was chosen. When the comparative results of the study are both cold and hot fluids. There are two different circuits in the
examined, it can be seen that the maximum error of temperature system: closed and open circuits. In the closed circuit, hot water
obtained by ANN and correlation is 1.94% and 4.20%, respectively. leaves the hot water tank and flows back to the same tank. In the
The maximum error of the mass flow rate is also 2.26% for ANN open circuit, the water coming from the cold water tank finally goes
predictions and 19.20% for the correlation. It was concluded in this to the waste water tank where the excess water is collected. The
study that predicting ability of the ANN methodology was superior
to the correlations.
Tan et al. [7] analyzed a compact, fin-tube heat exchanger to
predict its thermal performance with the use of ANN’s. ANN model
was compared to the conventional non-linear regression model.
The results of the study show that ANN model predicts the overall
heat transfer rate in this kind of heat exchanger with a high degree
of accuracy. ANN predictions are in much closer agreement to the
experimental data than the predictions with the use of a conven-
tional non-linear regression model. Xie et al. [8] reviewed studies
on thermal performance of fin and tube exchangers. Experimen-
tally determined and numerically computed Nusselt numbers and
friction factors were predicted using artificial neural nets. The
combined database consists of both experimental data and nu-
merical data obtained using computational fluid dynamics (CFD). It
is concluded that ANN yields superior prediction on thermal per-
formance of heat exchangers compared to power-law or multiple
correlations. Islamoglu et al. [9] also made heat transfer analysis in
corrugated channels using ANNs with a data set evaluated experi-
mentally. The prediction of Nusselt number was examined and
resulted in satisfactory estimations. Pacheco-Vega et al. [10] con-
ducted heat transfer analysis for a fin-tube heat exchanger based on
limited experimental data. The study predicts the heat transfer Fig. 1. Three dimensional solid models of the plates, a) Plate A, b ¼ 27.5
; b) Plate B,
rates of air-water heat exchangers using ANN’s. b ¼ 62.5

 C. Turk et al. / International Journal of Thermal Sciences 109 (2016) 263e269 265

Table 1
Geometrical properties of the plates used in the experiments.

Geometrical parameters Plate A Plate B Average

Chevron angle, b (
) 27.5 62.5 45

Dp (m) 0.058 0.058 0.058
Lw (m) 0.195 0.195 0.195
Lv (m) 0.694 0.694 0.694
Lp (m) 0.636 0.636 0.636
Average channel gap, b (mm) 3 3 3
Plate thickness, t (mm) 0.45 0.45 0.45
Wavy plate area, Al (m2) 0.12996 0.11913 0.12455
Flat plate area, Alp (m2) 0.114 0.114 0.114
Enlargement coefficient, : (Al/Alp) 1.14 1.045 1.0925

Fig. 3. A typical feed forward ANN architecture.

characteristics of the network. There are a lot of network configu-

Fig. 2. Schematic view of the test set-up (adapted from Ref. [13]).
flow rate, temperature at the inlets and exits and the pressure drop
values are measured. The water is heated up to the desired tem-
peratures with the help of resistance heaters. The data is collected
every 20 s. The experiments are performed for a wide range of flow
rate values. The maximum and minimum of the measured values
during the experiments are shown in Table 2. The average
geometrical properties of the two plates are used in the heat
transfer calculations for correlation development. 52 different sets
of data are utilized for the development of correlations and for the
employment of artificial neural networks. The correlations are
developed using modified Wilson Plot Methodology as explained in
Ref. [14].
2.3. Artificial neural network (ANN) based estimation methodology
An artificial neural network is a network which consists of
interconnected neurons. Each neuron is connected to the other
with a link called weight. These weights are used to carry the in-
formation between neurons. In a neural network, there are at least
three layers; input layer, hidden layer and output layer. Number of
hidden layers can be more than one. It depends on the
Table 2
Maximum and minimum values of the measured values.
Parameter Minimum
rations. Mostly, it is hard to find the correct configurations at the
first attempt. When a network is constructed, the numbers of
neurons and layers are determined by trial and error. Among the
various types of ANNs, feed forward neural network is the
commonly used one for engineering applications [1]. A typical feed
forward architecture is schematically shown in Fig. 3. This network
has one input layer, one hidden layer and one output layer.
Experimental or computational data is necessary to build ANN
configurations. The data obtained from experiments is divided into
two groups so that the ANN’s can be trained and tested. Usually
around 70e80% of the data is used for training [1]. Many network
configurations are used to obtain the most accurate prediction. The
number of hidden layers and the number of neurons are changed to
obtain new network configurations.
3. Results
3.1. Plate specific correlation development
Using the data obtained from experiments, correlations that fit
the gathered data from the experiments where water is used as the
working fluid, are developed. The correlation developed for Nusselt
number and friction factor using the experimental data are shown
below in Equations (1) and (2). Here, for the calculation of the
viscosity at the wall, the temperature of the wall is taken as the
average of the bulk temperatures of the hot and cold fluids. The
bulk temperatures of the hot and cold fluids are taken as the
arithmetic average of the inlet and outlet temperatures for the hot
and cold fluids. Therefore the wall temperature is the arithmetic
mean of the all four inlet and outlet temperatures for the hot and
cold fluids.

0:14
m
Nu ¼ 0:26023Re0:673 Pr1=3 (1)
mw
Maximum

Th,i (
C) 50 90.5
f ¼ 386500Re2:112 þ 0:7299 (2)
Th,o (
C) 12 77
The maximum uncertainties are 2.42% for Nusselt number
Tc,i (
C) 8 32
Tc,o (
C) 24 89.8 predictions which show the thermal performance and 5.32% for the
DPhot (kPa) 0.04 15 friction factor which determines the hydraulic performance.
DPcold (kPa) 0.14 13 The results of the correlations and the experimental data used
Vhot (m3/h) 0.5 6.05 for the development of these correlations are shown together in
Vcold (m3/h) 0.5 5.53
Fig. 4 for Nusselt number and Fig. 5 for friction factor. The x-axis is
266 C. Turk et al. / International Journal of Thermal Sciences 109 (2016) 263e269

Table 3
Geometrical properties for the plates used for comparison with mixed plate HEX.

Geometrical Parameters Plate 1 Plate 2 Plate 3

Chevron angle, b (
) 30 24 30
Dp (m) 0.035 0.1 0.035
Lw (m) 0.109 0.343 0.109
Lv (m) 0.37 0.732 0.665
Lp (m) 0.335 0.632 0.63
Average channel gap, b (mm) 2.76 2.64 2.76
Plate thickness, t (mm) 0.45 0.45 0.45
Wavy plate area, Al (m2) 0.035 0.266 0.073
Flat plate area, Alp (m2) 0.03 0.207 0.062
Enlargement coefficient, : (Al/Alp) 1.17 1.288 1.17

When Fig. 6 is examined, it is found out that the thermal per-

formance is not affected drastically, when two different plates are
used consequtively in the heat exchanger. However, as it is seen in
Fig. 7, friction factor drops when mixed plate HEX is used, where
the hydraulic performance is improved.

Fig. 4. Change of Nusselt number with Reynolds number (Experimental results) for the
mixed plate.
the Reynolds number for both graphs. The triangles are the
experimental measurements, whereas the curves represent the
functional relationships represented by the correlation developed
according to the experimental data. It is shown in the figures that,
Nusselt number increases with the Reynolds number. Since tur-
bulence increases with increasing Reynolds number, heat transfer
characteristics also develop. However when the trend for friction
factor with Reynolds number is examined in Fig. 5, it is seen that,
the friction factor decreases with increasing Reynolds number. At
low Reynolds numbers, the effect of friction factor is more obvious.
3.2. Comparison of the performance of mixed plate heat exchangers
with single plate heat exchangers
The correlations developed are compared with the previously
developed correlations of single plate heat exchangers. The
geometrical properties of the plates 1, 2, and 3 are shown in Table 3.
The detailed analysis of these plates is given in Ref. [14]. Fig. 6
shows the Nusselt number comparisons, whereas Fig. 7 shows
the comparisons for the friction coefficient.
3.3. ANN based thermal and hydraulic performance estimation
results
Nusselt number prediction and comparisons with correlation
results:
The data obtained from the experiments is composed of 52 sets of
data. It is divided into two for the training and the test of the ANN’s
as: 40 for training and 12 for tests. Several network configurations
are tested. The selection of the 40 and 12 data sets is totally random.
It is shown by Islamoglu [3] that, when around three quarters of all
the data is used for training and one quarter for tests, the results of
ANN’s are reliable. Therefore, approximately 75% of the data is
selected for training purposes, and the rest is left for tests.
The input values for Nusselt number prediction are given as:
Inlet temperature (Ti), outlet temperature (To), mass flow rate (m), _
Reynolds number (Re), Prandtl number (Pr), Viscosity ratio (m/mw),
whereas the output is the Nusselt number (Nu).
The errors obtained for the network configurations are shown in
Table 4. Fig. 8 shows the schematic for the network configuration.
In the names of the network structures, the first number shows the
number of inputs (6) and the last number shows the number of

Fig. 5. Change of friction factor with Reynolds number (Experimental results) for the Fig. 6. Nusselt number comparison with previously developed correlations for single
mixed plate. plate HEX.
 C. Turk et al. / International Journal of Thermal Sciences 109 (2016) 263e269 267

Fig. 7. Friction factor comparison with previously developed correlations for single
plate HEX.
Fig. 8. Network configuration.

outputs which is only Nusselt number and its value is 1 for all of the
cases tested. The quantity of the numbers in between, show the
number of hidden layers, for example for 6-3-1 network, there is Equation (5) shows the average accuracy of the prediction, while
one hidden layer for the prediction, whereas for 6-4-2-1 network, Equation (6) shows the scatter of the prediction [1]. All configura-
there are two hidden layers. tions are used to test the network with the data chosen randomly.
The relative error of every predicted value is defined as: Equations (5) and (6) are used to compare results.
As seen in Table 4, the error values obtained for 6 different
jAe  Ap j neural network configurations are compared with the experi-
Er ¼  100% (3)
Ae mental results, and 6-8-3-1 configuration is found to be the most
effective configuration.
where Ap is the predicted results, that is output of ANN, Ae is the Figs. 9 and 10 show the relative percentage errors for ANN
experimental data, that is the target output. Same error formulation predictions and correlations for the training and test data sets,
is used for the prediction of the relative errors for the correlation respectively. When Fig. 9 is examined, it is seen that, the errors in
method. Ap comes from the correlation instead of ANN for the the correlations are within 10e25%, whereas the errors for the ANN
estimation of the relative error of the correlation. The performance predictions are less than 10%. In Fig. 10, the error results for the test
of a network is obtained by calculating the root-mean-square (rms) data are shown. In both Figs. 9 and 10, it is observed that the
values of the output error relative errors calculated for the ANN predictions are less compared
vffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffi to the correlations and this shows that artificial neural nets may be
u M
e 
u1 X A  Ap 2 used as an alternative to correlations when there is enough data to
rms ¼ t (4) train the networks and if proper network configuration is selected.
M i¼1 Ae
Friction factor prediction and comparisons with correlation
results:
M is the number of data points used for the neural network. These
The friction factors which are an indicator of hydraulic perfor-
two error definitions are used to choose the best network config-
mance are also predicted. The experimental values are found using
uration from the trained networks [1].

1 XN
1 XN
Ae
R¼ Ri ¼ (5)
N i¼1 N i¼1 Ap

vffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffi
u N
uX ðR  Ri Þ2
s¼t (6)
i¼1
N

Table 4
Error values for ANN based Nusselt number predictions.

Network structure Training Test

Max relative error (%) rms R s

Correlation 25.7722 0.1644 1.172788 0.0600
6-3-1 14.5584 0.0629 1.009940 0.0738
6-4-1 73.0819 0.1379 0.921832 0.2214
6-5-1 16.3990 0.0586 1.016210 0.0774
6-6-1 31.8331 0.1506 1.116038 0.1910
6-4-2-1 35.4763 0.0933 0.978064 0.1078
6-8-3-1 10.0154 0.0369 0.969930 0.0657
Fig. 9. Relative percentage errors for 6-8-3-1 configuration for the training data set.
268 C. Turk et al. / International Journal of Thermal Sciences 109 (2016) 263e269

Fig. 11. Artificial neural network configuration for 6-2-1 network used for friction
factor prediction.

Fig. 10. Relative percentage errors for 6-8-3-1 configuration for the test data set.
the pressure drops measured during the experiments and plate
geometries. In order to predict the friction factors using artificial
neural networks, the inputs used are, Inlet temperature (Ti), outlet
temperature (To), Mass flow rate (m), _ Reynolds number (Re), Vis-
cosity ratio (m/mw), pressure drop (DP), and the single output is the
friction factor (f).
The results of the predictions for friction factor are shown in
Table 5 and the most effective network configuration used for
friction factor predictions is shown in Fig. 11. When the results in
Table 5 are examined, it is found out that the 6-2-1 configuration
gives the best performance compared to the other network con-
figurations tested and the correlation results. When the results of
the ANN predictions and the correlations are compared, the rms
errors obtained with the 6-2-1 configuration are 0.0353 and lower
compared to the rms value obtained from the correlations which is
0.0463.
correlation development for Nusselt number and friction factors.
Artificial neural networks (ANNs) are also used to estimate the
performance as an alternative to correlations. Different networks
with various numbers of hidden neurons and layers are used to find
the best configuration for predictions. The results show that, arti-
ficial neural networks can be an alternative to experimental cor-
relations for predicting thermal and hydraulic characteristics of
plate heat exchangers. They give better performance when
compared to correlations which are very common in heat transfer
applications. Especially for mixed plate configurations studied in
this research, where different plate types are used as a combination
in the complete heat exchanger, it is difficult to obtain a single
correlation that represents all the plates in the heat exchanger.
However, when ANN’s are used, it is easier to predict the perfor-
mance of mixed plate HEX and the predictions are more reliable
when compared to correlations.
Acknowledgments

This work is supported by Turkish Academy of Sciences (TUBA-

4. Discussion and conclusions GEBIP program) and Turkish Scientific and Research Council under
grant 112M173.
Experiments are performed to test the thermal and hydraulic
performance of gasketed plate heat exchangers (GPHE). A heat
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