An analysis of a crossflow two pass plate-flu compact heat exchanger, accounting for the effects of non-uniform inlet fluid flow due to headers is carried out using a finite element method. The heat exchanger effectiveness and pressure drops have been measured in the test rig. Using inlet flow non-uniformity models, the exchanger effectiveness and pressure drops and its deterioration due to the effects of flow non-uniformity are calculated for design case of the exchanger. Based on the flow non-uniformity effects, the exchanger hot side inlet and outlet headers have been modified to improve the exchanger effectiveness and pressure drop.
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