Coupling Characteristics Simulation of Single-Phase Flow and Heat Transfer for R134a/R245fa Mixture in a Cross-Corrugated Plate Heat Exchanger Channel

To investigate the influence of working fluid composition on the thermo-hydraulic performance of plate heat exchangers (PHEs) under single-phase sensible heat transfer conditions, a three-dimensional steady-state numerical model was developed for a transverse corrugated channel with a chevron angle of 60°. The governing equations were solved using the finite volume method implemented in ANSYS Fluent, in conjunction with the standard k–ε turbulence model. The analysis considered pure refrigerants R134a and R245fa, as well as their mixtures with mass ratios of 0.2, 0.5, and 0.8, with thermophysical properties assumed to be temperature-independent constants. The results indicate that as the mass fraction of R134a decreases from 1.0 to 0, the heat transfer coefficient (h) decreases from 1025 to 815 W/(m2·K), primarily attributed to the combined effects of reduced thermal conductivity and increased viscosity. Among the investigated cases, the R134a/R245fa mixture with a mass ratio of 0.8 provides the most favorable performance trade-off, exhibiting a heat transfer coefficient only 3.0% lower than that of pure R134a while achieving a 12.5% reduction in flow resistance compared with pure R245fa. Furthermore, the heat transfer coefficient is found to be weakly affected by heat flux in the range of 8000–20,000 W/m2; in contrast, increasing the mass flow rate from 0.001 to 0.005 kg/s enhances heat transfer coefficient by 65.1%, accompanied by a significant increase in pressure drop. Comparisons with established single-phase correlations for corrugated channels show average deviations of 6.5% for the Nusselt number and 3.8% for the friction factor. The present study provides useful guidance for working fluid selection and operational optimization of PHEs in applications dominated by sensible heat transfer, such as specific stages of heat pump cycles and medium-temperature waste heat recovery.