AMETECH | The “Ripple Code” of Plate Heat Exchangers

The core component of a plate heat exchanger is the plate. While plates from different manufacturers may appear similar at first glance, their heat-transfer efficiency and long-term operational stability can vary significantly.

The root of this difference is largely embedded in the corrugation design of the plates.

Plate heat exchanger

What is the function of corrugation?

The corrugations on the plate surface are not decorative; rather, they serve three core functions:

1. Enhance heat transfer

The corrugated structure causes the fluid to continuously change its flow direction within the interplate channels, thereby generating turbulence. The greater the degree of turbulence, the thinner the boundary layer, and the more efficient the heat transfer from the fluid to the plate surface.

2. Provide structural stiffness

The ridges and troughs of the corrugation create a structure akin to “reinforcing ribs,” enabling the thin sheet to withstand a certain level of pressure without undergoing permanent deformation.

3. Formation of the flow channel gap

The corrugations of adjacent plates come into contact, forming support points that ensure a uniform gap between the plates, allowing the fluid to flow evenly across the entire plate surface.

Key Parameters of Corrugation and Their Effects

1. Corrugation Depth

The corrugation depth determines the gap size between the plates.

Deep corrugations: With a larger flow channel clearance, they are suitable for media containing small amounts of particles, exhibiting relatively low pressure drop but slightly lower turbulence intensity.

Shallow corrugations: With a smaller flow channel gap, turbulence is more pronounced and the heat transfer coefficient is higher; however, pressure drop increases, and stricter cleanliness requirements for the working fluid are imposed.

Different operating conditions require matching different corrugation depths. Applying the same corrugation depth across all conditions will inevitably result in performance losses in certain scenarios.

2. Corrugation Angle

The angle between the corrugations and the vertical direction is a key parameter influencing heat transfer performance.

Small angle (approximately 30°): lower flow resistance, with a relatively lower heat transfer coefficient.

Large angle (approximately 60°): exhibits higher flow resistance and a significant increase in the heat transfer coefficient.

A common design employs alternating double‑angle corrugations on the same plate, which enhances heat transfer while controlling the increase in pressure drop.

3. Corrugated Cross-Section Shape

The cross-section of the corrugations may be triangular, trapezoidal, or sinusoidal. The specific shape of the cross-section influences the fluid’s flow characteristics and its tendency to foul. The smoother the transition between cross-sectional shapes, the fewer local vortices and dead zones there are, and the greater the resistance to fouling.

4. Distribution of Contact Points on the Corrugation

The corrugations of adjacent plates intersect, creating a dense network of contact support points. The density and arrangement of these contact points influence the plate’s pressure‑bearing capacity and the degree of lateral fluid disturbance. A well‑designed distribution of contact points can enhance turbulence without increasing pressure drop.

Diversion Zone

In addition to the heat-transfer zone (corrugated zone), the flow‑guiding design of the plates is equally critical.

The flow distribution zone is located between the corner ports and the heat exchange zone, and its function is to evenly distribute the fluid entering the plate pack into each flow channel. A poorly designed flow distribution zone can result in:

Deflection: Some flow channels have excessively high flow rates, while others have excessively low flow rates.

Dead zone: In certain areas, the fluid barely flows, allowing contaminants to accumulate.

Local pressure drop: Additional resistance is generated at the runner inlet.

A high-quality flow‑diverting zone design should ensure that, upon entering through the corner ports, the fluid spreads uniformly across the entire plate width in the shortest possible path and enters the heat‑transfer zone with minimal energy loss.

Performance Differences Among Various Corrugation Designs

The three types listed in the table represent distinct design orientations. In practical engineering applications, the most suitable corrugation configuration should be selected based on a comprehensive assessment of factors such as fluid properties, allowable pressure drop, and cleaning requirements.

Technical Features of Ametech Corrugated Plate Design

In its plate‑corrugation design, AMETECH adopts a “service‑condition‑matching” approach rather than relying on a single plate configuration to cover all applications.

Multi-ribbed scheme system

Ametech offers a wide range of plate configurations, featuring various corrugation depths and angles, to meet diverse operating conditions—spanning high heat-transfer efficiency and low flow resistance, as well as applications involving clean media and those prone to fouling. Users can select the most suitable plate design based on the specific properties of the process fluid and the system’s allowable pressure-drop margin.

Optimized flow‑diversion zone design

The flow‑diverting zone of the AMETECH plate features a streamlined transition design that minimizes local resistance and flow dead zones. While this design is hardly noticeable under normal operating conditions, over long-term operation it translates into more uniform fouling distribution and more consistent performance retention.

Contact Point Layout Optimization

By leveraging computational fluid dynamics (CFD) simulations to guide the design, AMETECH has optimized the density and arrangement of plate contact points, striking a balance among pressure resistance, heat transfer efficiency, and pressure drop.

Selection of Plate Thickness and Material Matching

Based on design pressure and the corrosivity of the process fluid, AMETECH offers a range of plate thickness options and material choices—including 304, 316L, titanium, and Hastelloy—to ensure that the corrugated structure remains stable over long-term operation.

The corrugation design of the plates is one of the core technologies of plate heat exchangers, directly determining the equipment’s heat transfer efficiency, pressure drop characteristics, and fouling resistance. Ametech’s sustained investment and technological expertise in this field ultimately translate into heat exchange equipment that is highly tailored to the operating conditions and delivers stable, long-term performance.

Keywords:Heat exchanger, system, vessel