Bubble Nucleation and Behavior on Micro Square Heaters

In this study, micro square polysilicon heaters having dimensions of 65 × 65 μm² and 100 × 100 μm² were fabricated on a silicon dioxide layer, and bubble nucleation experiments on the heaters were performed. Bubble nucleation temperature was measured using a bridge circuit, and the photographs of bubble nucleation and subsequent growth were taken by a 35-mm camera with a μs flash unit. Measured bubble nucleation temperatures were found to be closer to the superheat limit of the working fluid of FC-72. A quasi-1-D solution obtained from the 2-D heat diffusion equation yielded proper temperature distribution of the square heaters at steady state; however, it failed to predict the temperature rise up to the steady state. The time-dependent temperatures similar to the observed values can be obtained with much lower value of thermal diffusivity than the bulk property of the polysilicon heater used. For the 100 × 100 μm² square heater, nucleation of several bubbles was observed, but for the 65 × 65 μm² heater, only that of one bubble was observed.     

An experimental study of heater size effect on micro bubble generation

An experimental study of the heater size effect on micro boiling is reported in detail. Using a 1.66-ms-wide heating pulse, boiling in subcooled water was investigated on a series of micron/submicron thin film Pt heaters with various feature sizes ranging from 0.5 μm to 70 μm. It was found that there existed a critical heater size (10 μm): single spherical bubble generation with heater’s feature size less than 10 μm; oblate vapor blanket on the heater surface with the size larger than 10 μm. The bubble dynamics was studied by the visualization of the bubble nucleation process with a high-speed CCD. The onset bubble nucleation temperature was measured by using each Pt heater as a resistive temperature sensor. The formation of the oblate vapor blanket was attributed to the condensation effect of the vapor outside the superheated zone. The analysis was further validated by generating spherical bubble on heater with size larger than 10 μm with a longer heating pulse.     

Nucleation site interaction between artificial cavities during nucleate pool boiling on silicon with integrated micro-heater and temperature micro-sensors

Nucleate boiling is commonly characterised as a very complex and elusive process. Many involved mechanisms are still not fully understood and more detailed consideration is needed. In this study, bubble growth from micro-fabricated artificial cavities with varied spacing on a horizontal 380 μm thick silicon wafer was investigated. The horizontally oriented boiling surface was heated by a thin resistance heater integrated on the rear of the silicon test section. The temperature was measured using 16 integrated micro-sensors situated on the boiling surface, each with an artificial cavity located in its geometrical centre. Experiments with three different spacings 1.5, 1.2 and 0.84 mm in between cavities with a nominal mouth diameter of 10 μm and a depth of 80 μm were undertaken. To conduct pool boiling experiments, the test section was mounted inside a closed stainless steel boiling chamber with optical access and completely immersed in degassed fluorinert FC-72. Bubble nucleation, growth and detachment at 0.5 and 1 bar absolute pressure were investigated using high-speed imaging. The effect of decreasing inter-site distance on bubble nucleation frequency, bubble departure frequency and diameter with increasing wall superheat is presented. Furthermore, the frequency of horizontal bubble coalescence was determined. The regions of influence on the measured frequencies and bubble departure diameter were compared with recently published findings.     

Boiling propagation of water on a smooth film heater surface

Boiling propagation of water is investigated experimentally at atmospheric pressure using a small platinum film heater having a surface smoothness of nanometer order. The test water is highly superheated up to approximately 140 K before the inception of boiling on the stepwise powered heater. Boiling is triggered at the prescribed wall superheat before spontaneous inception by generating a boiling bubble at a local section of the heater. The behavior of the propagating bubble is revealed by stroboscopic photography. The propagation takes place at wall superheats larger than approximately 50 K, and the propagation velocity increases significantly with wall superheat up to 24 m/s. The propagating front is followed by prompt collapse of the bubble at the tail, resulting in rapid migration of the boiling region. The measured propagation velocity is compared with the value predicted using an analytical model reported in the literature, and reasonable agreement is shown over the entire range of the wall superheat.     

Bubble growth characterization during fast boiling in an enclosed geometry

Microboiling is commonly used in thermal inkjet atomizers (TIJ) and microelectromechanical (MEM) devices. The TIJ and MEM devices performance is closely related to the dynamics of the bubble used to operate them; therefore, it is important to determine the conditions of input energy and power leading to specific bubble dynamics. The objective in this work is the characterization, in a confined space, of the bubble dynamics on a range of input conditions of energy and power and what is the effect of the input conditions on the bubble extractable mechanical efficiency. Mechanical efficiency is defined by the ratio of the integral of the mechanical work (work done by the bubble expansion due to the elevated internal pressure relative to atmospheric pressure minus the increase in bubble surface energy) to the total energy input to the microheater. Bubbles are generated with energies of 7–17 μJ under high heating rates and short pulses in deionized water. Resulting nucleation temperature measurements are consistent with homogeneous nucleation. The bubble lifecycle shows strong dependence on the input heater energy and input heating rate. This work presents new results in bubble growth where growth–shrink–growth derived from specific energy conditions. The bubble growth–shrink–growth may be due to subcooled fluid, local variation in the pressure field, and by the surface tension driven change in curvature of the bubble. Mechanical bubble efficiencies result in small values suggesting most of the energy applied to the heater is distributed in other processes which may include increasing the internal energy of the heater film and the fluid.     

Pool boiling heat transfer on small heaters: effect of gravity and subcooling

Measurements of space and time resolved subcooled pool boiling of FC-72 in low, earth, and high gravity environments were made using a microscale heater array. Data from each heater in the array were synchronized with high-speed digital video. The boiling behavior was dominated by the formation of a large primary bubble on the surface which acted as a “sink” for many smaller bubbles surrounding it. Dryout of the heater occurred under the primary bubble. For a given superheat, this primary bubble was observed to increase in size with bulk fluid temperature. Boiling curves at various subcoolings and gravity levels are presented.     

Flow Boiling in an Inclined Channel With Downward-Facing Heated Upper Wall

Wall boiling and bubble population balance equations combined with a two-fluid model are employed to predict boiling two-phase flow in an inclined channel with a downward-facing heated upper wall. In order to observe the boiling behavior on the inclined, downward-facing heated wall, a visualization experiment was carried out with a 100 mm × 100 mm of the cross section, 1.2-m-long rectangular channel, inclined by 10° from the horizontal plane. The size of the heated wall was 50 mm by 750 mm and the heat flux was provided by Joule heating using DC electrical current. The temperatures of the heater surface were measured and used in calculating heat transfer coefficients. The wall superheat for 100 kW/m² heat flux and 200 kg/m²s mass flux ranged between 9.3°C and 15.1°C. High-speed video images showed that bubbles were sliding, continuing to grow, and combining with small bubbles growing at their nucleation sites in the downstream. Then large bubbles coalesced together when the bubbles grew too large to have a space between them. Finally, an elongated slug bubble formed and it continued to slide along the heated wall. For these circumstances of wall boiling and two-phase flow in the inclined channel, the existing wall boiling model encompassing bubble growth and sliding was improved by considering the influence of large bubbles near the heated wall and liquid film evaporation under the large slug bubbles. With this improved model, the predicted wall superheat agreed well with the experimental data, while the RPI model largely overpredicted the wall superheat.     

Subcooled boiling incipience on a highly smooth microheater

Subcooled boiling incipience on a highly smooth microscale heater (270 μm × 270 μm) submerged in FC-72 liquid is investigated. Using high-speed imaging and a transient heat flux measurement technique, the mechanics of homogeneous nucleation on the heater are elucidated. Bubble incipience on the microheater was observed to be an explosive process. It is found that the superheat limit of boiling liquid is required for bubble incipience. It is concluded that boiling incipience on the microheater is a homogeneous liquid–vapor phase change process. This is in contrast to recent observations of low-superheat heterogeneous nucleation on metallic surfaces of rms roughness ranging from 4 to 28 nm [T.G. Theofanous, J.P. Tu, A.T. Dinh, T.N. Dinh, The boiling crisis phenomenon part I: nucleation and nucleate boiling heat transfer, Exp. Therm. Fluid Sci. 26 (2002) 775–792; Y. Qi, J.F. Klausner, Comparison of gas nucleation and pool boiling site densities, J. Heat Transfer 128 (2005) 13–20; Y. Qi, J.F. Klausner, Heterogeneous nucleation with artificial cavities, J. Heat Transfer 127 (2005) 1189–1196]. Following the explosive bubble incipience, the boiling process on the microheater can be maintained at much lower superheats. This is mainly due to the necking during bubble departure that leaves an embryo from which the next-generation bubbles grow.     

The growth and collapse of a micro-bubble under pulse heating

The possibility of using a micro-thermal bubble, generated by a micro-heater under pulse heating, as an actuator for applications in micro-bio-analytical systems is investigated in this paper. The perturbation force, generated when the micro-thermal bubble is formed instantaneously, can be used to promote such actions as mixing in the solution of a micro-reactor. Under pulse heating, a specially designed non-uniform width micro-heater (10 × 3 μm²) can induce highly localized near-homogeneous nucleation and results in periodic generation of stable single bubbles in DI water. The single bubble appears precisely on the narrow part of the micro-heater with size restricted within the superheated region in the fluid. The growth and collapse of the bubble, recorded by a high-speed CCD, is shown to be asymmetric with time if the pulse width is at milliseconds in time scale. This asymmetric behavior is very much different from those in thermal ink-jet printers. The bubble behavior under different heating duration, ranging from microseconds to milliseconds, is experimentally studied. A transient 3-D heat conduction numerical simulation is carried out to study the temperature field of the fluid before the nucleation process. To evaluate the perturbation area of the micro-bubble, submicron particles with diameter of 0.96 μm were placed in the fluid and their dynamic response during the transient bubble formation is recorded.     

The Influence of System Pressure on Bubble Coalescence in Nucleate Boiling

Boiling is one of the most effective heat transfer mechanisms. In spite of a long time of research, the physical fundamentals are still not sufficiently understood. Pursuing the objective to predict heat transfer based on physical and geometrical properties, experimental and numerical investigations are conducted at the institute of the authors. The focus of the presented research is the coalescence of two single bubbles under varying pressure conditions. In the experiment a thin stainless-steel foil is used as a Joule heater. The experiments were performed in a pressure range of 300–1000 mbar using FC72 as working fluid. Two types of heaters with a distance between two artificial nucleation sites of 300 μm (type 3) and 500 μm (type 5) were used. The experimental results indicate a strong dependence of the occurrence of bubble coalescence on pressure. For the type 5 heater, a Gaussian distribution for the coalescence frequency when plotted over pressure is observed. Experimental results with the type 3 heater show a similar distribution of the frequency with a shifted maximum. Further, it is shown that during bubble coalescence a small droplet can remain inside the bubble and enhance the heat transfer, which is attributed to an additional thin film region. The formation of this remaining droplet is sensitive to system pressure. Numerical investigations of bubble coalescence were conducted with the computational fluid dynamics (CFD) software OpenFOAM. In OpenFOAM, dynamic mesh handling allows high spatial resolution at the phase boundary, which is captured with the volume-of fluid method. Evaporation and a subgrid microscale model were implemented in the flow solver to account for evaporation at the phase boundary and the three-phase contact line. The results show a strong dependence of bubble dynamics and coalescence on contact angle and bubble growth rate. Although it was possible to observe the creation of the residual droplet, more effort needs to be put into finding appropriate initial conditions.     

Pumping Action by Boiling Propagation in a Microchannel

The use of boiling propagation as the actuation mechanism of micropumps is proposed. The process of boiling propagation along a film heater surface, the propagation velocity, propagating bubble size, maximum repetition frequency, and the wall superheat conditions under which propagation occurs are investigated using ink for a thermal inkjet printer under pool boiling conditions. A prototype micropump that uses boiling propagation is developed. A film heater placed facing the microchannel is powered stepwise over a short duration and unidirectional boiling propagation over the entire heater length is triggered at a high wall superheat by generating a vapor bubble at the end of the heater. A continuous pumping action in a U-shaped microchannel via boiling propagation repeated at a prescribed frequency of up to 20 Hz is confirmed based on the head difference generated between liquid columns in the vertical sections.     

Coalescence of bubbles in nucleate boiling on microheaters

In this paper, an experiment was performed which is based on a heating surface consisting of microheaters where the temperature of each heater can be individually controlled by an electronic feedback loop. The power consumed by the heaters throughout the cycle of individual bubble growth, coalescence, detachment and departure was measured at high frequencies, thus the heat flux and its variation were obtained. By a careful timing and control of two individual microheaters, we were able to produce two individual bubbles side-by-side. The coalescence would takes place when they grow to a certain size that allows them to touch each other. We have recorded two major heat flux spikes for a typical cycle of boiling with coalescence. The first one corresponds to the nucleation of bubbles; the second one is for the coalescence of the two bubbles. We found that the heat flux variation is closely related to the bubble dynamics and bubble-bubble interaction. By comparing with the single bubble results without coalescence, we also found that the heat transfer is highly enhanced due to the coalescence.     

Thermal performance investigation of double pass-finned plate solar air heater

In this paper, the double pass-finned plate solar air heater was investigated theoretically and experimentally. An analytical model for the air heater was presented. Numerical calculations had been performed under Tanta (latitude, 30° 47′N and longitude, 31°E) prevailing weather conditions. The theoretical predictions indicated that the agreement with the measured performance is fairly good. Comparisons between the measured outlet temperatures of flowing air, temperature of the absorber plate and output power of the double pass-finned and v-corrugated plate solar air heaters were also presented. The effect of mass flow rates of air on pressure drop, thermal and thermohydraulic efficiencies of the double pass-finned and v-corrugated plate solar air heaters were also investigated. The results showed that the double pass v-corrugated plate solar air heater is 9.3–11.9% more efficient compared to the double pass-finned plate solar air heater. It was also indicated that the peak values of the thermohydraulic efficiencies of the double pass-finned and v-corrugated plate solar air heaters were obtained when the mass flow rates of the flowing air equal 0.0125 and 0.0225 kg/s, respectively.     

提高热电厂效率的几项措施

从热经济性角度提出提高热电厂效率的几项技术和措施:通过凝汽器补充软化水,将外供蒸汽过热度降低;使用喷射式混合加热器回收热力除氧器排汽,作为生水加热器;利用压力匹配器代替减压减温器;用两相流加热器代替面式高压加热器等。     

Numerical study of patterns and influencing factors on flow boiling in vertical tubes by thermal LBM simulation

Heat transfer and flow pattern of flow boiling in vertical tube are investigated numerically based on the phase-change Lattice Boltzmann method (LBM) which includes an improved pseudo-potential LB model and a thermal LB model. Two-dimensional numerical simulations are carried out under constant heat flux conditions for the first time. The processes of growth, slippage, detachment and coalescence of the bubbles are captured to verify the correctness of the model. The effects of gravity, contact angle and wall superheat on bubble departure diameter and nucleation waiting time are illustrated. The multiple flow patterns, single-phase flow, bubble flow, slug flow and DNB have been illustrated with the behaviors of bubble nucleation, growth, departure, and coalescence. Some basic features of flow boiling have been clearly observed in the simulation. The influences of several factors such as heat flux, Reynolds number, the width of flow channel, and the width of nucleation point on flow boiling especially on the point of DNB are investigated. The numerical results show that the DNB could be avoided by reducing the heating density, increasing the Reynolds number, increasing the width of the tube and reducing the heating concentration.     

Dynamic characteristics of transient boiling on a square platinum microheater under millisecond pulsed heating

A series of experimental investigations of boiling incipience and bubble dynamics of water under pulsed heating conditions for various pulse durations ranging from 1 ms to 100 ms were conducted. Using a very smooth square platinum microheater, 100 μm on a side, and a high-speed digital camera, the boiling incipience was observed and investigated as a function of the bulk temperature of the microheater, pulse power level, and pulse duration. Given a specific pulse duration, for low pulse power levels, there would be no bubble nucleation or bubble mergence, for moderate pulse power levels, individual bubbles generated on the heater merged to form a single large bubble, while for high pulse power levels, the rapid growth of the individual bubbles and subsequent bubble interaction, resulted in a reduction in bubble coalescence into a single larger bubble, referred to as bubble splash. The transient heat flux range at which bubble coalescence occurs was identified experimentally, along with the temporal variations of bubble size, bubble interface velocity and interface acceleration.     

An experimental investigation of bubble nucleation of a refrigerant in pressurized boiling flows

An experimental investigation is performed to determine the effect of system pressure and heat flux on flow boiling and associated bubble characteristics of a refrigerant in a narrow vertical duct. A high-pressure flow boiling test loop was built and TLC (thermo-chromic liquid crystal) was applied to the back of the heater foil for high resolution and accurate measurement of heater surface temperature. Refrigerant R-134a is used as the test fluid at different pressures ranging from 690 to 827 kPa and different heat fluxes to quantify their influence in bubble characteristics such as bubble nucleation, growth, departure, and coalescence. Two synchronized high resolution and high-speed cameras are used to simultaneously capture TLC images as well as bubbling activities at high frame rates. By varying flow rate and system pressure, TLC and bubble images were captured and analyzed. Results show that the bubble generation frequency and size increase with heat flux. An increase in pressure from 690 to 827 kPa increased the bubble frequency and size by about 32 Hz and 20 μm, respectively. Bubble coalescence was also observed after departure from the nucleation site.     

On the Relation between Nucleation Site Density and Critical Heat Flux of Pool Boiling

ABSTRACT

It is traditionally accepted that the critical heat flux (CHF) decreases with increasing nucleation site density (NSD). However, such a CHF-NSD relation was no longer observed in the BETA-B experiment performed on nano-film heaters; instead the increase of NSD resulted in a gain in CHF. To address this seeming contradiction in the relation between critical heat flux and nucleation site density, the present work employed probabilistic analysis to reveal the different tendencies. A concept of effective NSD was proposed, which concerns the active nucleation sites appear within a bubble lifetime, and the resulting bubbles have the chance of direct interaction. We assumed that the boiling crisis on a heater surface is mainly induced by two mechanisms: dry spot expanding in isolated bubble regime for low-NSD surface, coalescence of dry spots under multiple bubbles in fully developed nucleate boiling regime for high-NSD surface, or a combination of the two in the transition regime for medium-NSD surface. Accordingly, we estimated the critical heat flux of each boiling regime at which the boiling crisis occurs. The result indicated that there is a threshold of nucleation site density below which the increase of NSD is contributing to CHF enhancement, while the trend is inverted beyond the threshold.     

Investigation of thermal performance of-double pass-flat and v-corrugated plate solar air heaters

In this paper, the double pass flat and v-corrugated plate solar air heaters are investigated theoretically and experimentally. Analytical models for the air heater with flat and v-corrugated plates are presented. Numerical calculations have been performed under Tanta (latitude, 30^° 47^′ N) prevailing weather conditions. The theoretical predictions indicated that the agreement with the measured performance is fairly good. Comparisons between the measured outlet temperatures of flowing air, output power and overall heat losses of the flat and v-corrugated plate solar air heaters are also presented. The effect of mass flow rates of air on pressure drop, thermal and thermo hydraulic efficiencies of the flat and v-corrugated plate solar air heaters are also investigated. The results showed that the double pass v-corrugated plate solar air heater is 11-14% more efficient compared to the double pass flat plate solar air heater. It is also indicated that the peak values of the thermo hydraulic efficiencies of the flat and v-corrugated plate solar air heaters are obtained when the mass flow rate of the flowing air is 0.02 kg/s.     

Holographic interferometric study of heat transfer to a sliding vapor bubble

Heat transfer associated with a vapor bubble sliding along a downward-facing inclined heater surface was studied experimentally using holographic interferometry. Volume growth rate of the bubbles as well as the rate of heat transfer along the bubble interface were measured to understand the mechanisms contributing to the enhancement of heat transfer during sliding motion. The heater surface was made of polished silicon wafer (length 185 mm and width 49.5 mm). Experiments were conducted with PF-5060 as test liquid, for liquid subcoolings ranging from 0.2 to 1.2 °C and wall superheats from 0.2 to 0.8 °C. The heater surface had an inclination of 75° to the vertical. Individual vapor bubbles were generated in an artificial cavity at the lower end of the heater surface. High-speed digital photography was used to measure the bubble growth rate. The temperature field around the sliding bubble was measured using holographic interferometry. Heat transfer at the bubble interface was calculated from the measured temperature field. Results show that for the range of parameters considered the bubbles continued to grow, with bubble growth rates decreasing with increasing liquid subcooling. Heat transfer measurements show that condensation occurs on most of the bubble interface away from the wall. For the parameters considered condensation accounted for less than 12% of the rate heat transfer from the bubble base. In this study the heater surface showed no drop in temperature as a result of heat transfer enhancement during bubbles sliding.