Two-Phase Flow Distribution in Plate Heat Exchangers Using a Coupled CFD–Distributed Parameter Model

Abstract

Plate heat exchangers (PHEs) play a critical role in the energy efficiency of heat pump systems. However, non-uniform two-phase flow distribution across parallel channels remains a key limitation, as it may cause local dryout and degrade heat transfer performance. To address the limitations of existing prediction approaches, a hybrid modeling framework coupling computational fluid dynamics (CFD) simulations with a distributed parameter model is developed. The model is validated against experimental data under 12 representative operating conditions. The results show that the average prediction errors for the total mass flow rate, pressure drop, and heat transfer rate are within 3%, ±10%, and ±5%, respectively. The influences of refrigerant outlet conditions and inlet distributor geometry on flow distribution uniformity are systematically investigated, identifying the dominant factors governing pressure drop and the mechanism by which distributor orientation improves uniformity. Quantitative optimization shows that an orifice orientation of 225° reduces flow non-uniformity by 67.8% and enhances the heat transfer rate by 4.33% compared with the distributor-free design. The proposed method is robust across various operating scenarios and provides a reliable, quantitative tool for optimizing PHE inlet distributor designs.