Research on flow channel structure optimization of cyclopentane regenerator printed circuit heat exchanger

To enhance the cyclopentane regenerator performance of the Organic Rankine Cycle system, this study optimizes the flow channel structure of the printed circuit heat exchanger via CFD multi-physics coupling simulation. Three-dimensional models of straight-flow, reflux-flow, and cross-flow channels are established, and their thermo-hydraulic performances are systematically compared. Results show that the cross-flow channel achieves the best overall performance, with a cold-side pressure drop of 0.65 kPa, hot-side pressure drop of 0.24 kPa, and heat-transfer rate of 2.39 kW. The heat-transfer rate is 198.75% higher than the straight-flow channel, while the cold and hot-side pressure drops are reduced by 60.61% and 87.88% compared with the reflux-flow channel. Heat-transfer correlations for hot and cold sides are fitted using multi-condition data and genetic algorithm. Experimental verification shows errors within 15% for the hot side and 18% for the cold side, providing a high-precision theoretical model for Printed Circuit Heat Exchanger engineering design in Organic Rankine Cycle systems.