Experimental and theoretical study of orientation effects on flow boiling CHF

The effects of orientation on flow boiling critical heat flux (CHF) were investigated using high-speed video and microphotographic techniques. Interfacial features were measured just prior to CHF and statistically analyzed. A dominant wavy vapor layer regime was observed for all relatively high-velocities and most orientations, while several other regimes were encountered at low velocities, in downflow and/or downward-facing heated wall orientations. The interfacial lift-off model was modified and used to predict the orientation effects on CHF for the dominant wavy vapor layer regime. The photographic study revealed a fairly continuous wavy vapor layer travelling along the heated wall while permitting liquid contact only in wetting fronts, located in the troughs of the interfacial waves. The waves, which were generated at an upstream location, had a tendency to preserve a curvature ratio as they propagated along the heated wall. CHF commenced when wetting fronts near the outlet were lifted off the wall. This occurred when the momentum of vapor normal to the wall exceeded the pressure force associated with interfacial curvature. The interfacial lift-off model is shown to be very effective at capturing the overall dependence of CHF on orientation.     

Experimental and theoretical study of critical heat flux in vertical upflow with inlet vapor void

This study explores the mechanism of flow boiling critical heat flux (CHF) for FC-72 in a 2.5 mm × 5 mm vertical upflow channel that is heated along its 2.5 mm sidewall downstream of an adiabatic development section. Unlike most prior CHF studies, where the working fluid enters the channel in liquid state, the present study concerns saturated inlet conditions with finite vapor void. Temperature measurements and high-speed video imaging techniques are used to investigate the influence of the inlet vapor void on interfacial behavior at heat fluxes up to CHF as well during the CHF transient. The flow entering the heated portion of the channel consists of a thin liquid layer covering the entire perimeter surrounding a large central vapor core. Just prior to CHF, a fairly continuous wavy vapor layer begins to develop between the liquid layer covering the heated wall and the heated wall itself, resulting in a complex four-layer flow consisting of the liquid layer covering the insulated walls, the central vapor core, the now separated liquid layer adjacent to the heated wall, and the newly formed wavy vapor layer along the heated wall. This behavior in captured in a new separated control-volume-based model that facilities the determination of axial variations of thicknesses and mean velocities of the four layers. Incorporating the results of this model in a modified form of the Interfacial Lift-off CHF Model is shown to provide fairly good predictions of CHF data for mass velocities between 185 and 1600 kg/m² s, evidenced by a mean absolute error of 24.52%.     

Flow boiling CHF in microgravity

Poor understanding of flow boiling in microgravity has recently emerged as a key obstacle to the development of many types of power generation and life support systems intended for space exploration. This study examines flow boiling CHF in microgravity that was achieved in parabolic flight experiments with FC-72 onboard NASA’s KC-135 turbojet. At high heat fluxes, bubbles quickly coalesced into fairly large vapor patches along the heated wall. As CHF was approached, these patches grew in length and formed a wavy vapor layer that propagated along the wall, permitting liquid access only in the wave troughs. CHF was triggered by separation of the liquid-vapor interface from the wall due to intense vapor effusion in the troughs. This behavior is consistent with, and accurately predicted by the Interfacial Lift-off CHF Model. It is shown that at low velocities CHF in microgravity is significantly smaller than in horizontal flow on earth. CHF differences between the two environments decreased with increasing velocity, culminating in virtual convergence at about 1.5 m/s. This proves it is possible to design inertia-dominated systems by maintaining flow velocities above the convergence limit. Such systems allow data, correlations, and/or models developed on earth to be safely implemented in space systems.     

Photographic study and modeling of critical heat flux in horizontal flow boiling with inlet vapor void

This study explores the mechanism of flow boiling critical heat flux (CHF) in a 2.5 mm × 5 mm horizontal channel that is heated along its bottom 2.5 mm wall. Using FC-72 as working fluid, experiments were performed with mass velocities ranging from 185–1600 kg/m²s. A key objective of this study is to assess the influence of inlet vapor void on CHF. This influence is examined with the aid of high-speed video motion analysis of interfacial features at heat fluxes up to CHF as well as during the CHF transient. The flow is observed to enter the heated portion of the channel separated into two layers, with vapor residing above liquid. Just prior to CHF, a third vapor layer begins to develop at the leading edge of the heated wall beneath the liquid layer. Because of buoyancy effects and mixing between the three layers, the flow is less discernible in the downstream region of the heated wall, especially at high mass velocities. The observed behavior is used to construct a new separated three-layer model that facilitates the prediction of individual layer velocities and thicknesses. Combining the predictions of the new three-layer model with the interfacial lift-off CHF model provides good CHF predictions for all mass velocities, evidenced by a MAE of 11.63%.     

Photographic study of high-flux subcooled flow boiling and critical heat flux

This study examines both high-flux flow boiling and critical heat flux (CHF) under highly subcooled conditions using FC-72 as working fluid. Experiments were performed in a horizontal flow channel that was heated along its bottom wall. High-speed video imaging and photomicrographic techniques were used to capture interfacial features and reveal the sequence of events leading to CHF. At about 80% of CHF, bubbles coalesced into oblong vapor patches while sliding along the heated wall. These patches grew in size with increasing heat flux, eventually evolving into a fairly continuous vapor layer that permitted liquid contact with the wall only in the wave troughs between vapor patches. CHF was triggered when this liquid contact was finally halted. These findings prove that the CHF mechanism for subcooled flow boiling is consistent with the interfacial lift-off mechanism proposed previously for saturated flow boiling.     

Effect of the Exit Condition on the Performance of In-Tube Condensers

Data collected from the open literature plus some new, unpublished data show that the exit condition with in-tube condensation can change the flow regimes, introduce certain types of instabilities, and alter flooding velocities. All the possible orientations are considered: horizontal, vertical with vapor downflow, and vertical with vapor upflow (refluxing).     

Prediction of liquid hydrogen flow boiling critical heat flux condition under microgravity based on the wall heat flux partition model

Critical heat flux (CHF) of liquid hydrogen (LH2) flow boiling under microgravity is vital for designing space cryogenic propellant conveying pipe since the excursion of wall temperature may cause system failure. In this study, a two-dimensional axisymmetric model based on the wall heat flux partition (WHFP) model was proposed to predict the CHF condition under microgravity including the wall temperature and the CHF location. The proposed numerical model was validated to demonstrate a good agreement between the simulated and experimentally reported results. Then, the wall temperature distribution and the CHF location under different gravity conditions were compared. In addition, the WHFP and vapor-liquid distribution along the wall under microgravity were predicted and its difference with terrestrial gravity condition was also analysed and reported. Finally, the effects of flow velocity and inlet sub-cooling on the wall temperature distributions were analysed under microgravity and terrestrial gravity conditions, respectively. The results indicate that the CHF location moves upstream about 5.25 m from 1g to 10⁻⁴g since the void fraction near the wall reaches the breakpoint of CHF condition much earlier under the microgravity condition. Furthermore, the increase of the velocity and decrease of the sub-cooling have smaller effects on the CHF location during LH2 flow boiling under microgravity.     

Thermal Physics and Critical Heat Flux Characteristics of Al2O3–H2O Nanofluids

This study investigates the influence of the thermal physics of nanofluids on the critical heat flux (CHF) of nanofluids. Thermal physics tests of nanoparticle concentrations ranged from 0 to 1 g/L. Pool boiling experiments were performed using electrically heated NiCr metal wire under atmospheric pressure. The results show that there was no obvious change for viscosity and a maximum enhancement of about 5 to 7% for thermal conductivity and surface tension with the addition of nanoparticles into pure water. Consistently with other nanofluid studies, this study found that a significant enhancement in CHF could be achieved at modest nanoparticle concentrations (<0.1 g/L by Al₂O₃ nanoparticle concentration). Compared to the CHF of pure water, an enhancement of 113% over that of nanofluids was found. Scanning electron microscope photos showed there was a nanoparticle layer formed on the heating surface for nanofluid boiling. The bubble growth was photographed by a camera. The coating layer makes the nucleation of vapor bubbles easily formed. Thus, the addition of nanoparticles has active effects on the CHF.     

Capillary column enhanced CHF microgravity flow boiling

Flow boiling heat transfer under microgravity conditions can be extended and enhanced by means of using porous stacks, or capillary columns, arranged on top of a flat heated surface. Under these conditions, body forces are negligible to remove the generated vapor away from the hot surface, which eventually hinders liquid from reaching it. It is possible to increase the critical heat flux (CHF) by having porous stacks symmetrically arranged on this surface; which draws the liquid phase towards it by means of capillary forces. Various flow regimes in the capillary enhanced surface flow boiling can be identified. These include: the regime where the liquid is supplied between the columns, the regime where the liquid flow is controlled by liquid capturing and the viscous drag-capillarity in the columns, and the critical heat flux. For the theoretical model, the expression for the interfacial lift-off model critical heat flux was interpreted based on customizable parameters instead of those imposed by the physics of the flow. This study indicates a potential improvement in CHF by having an inter-column spacing smaller than the critical wavelength for a plain surface. There is also a potential benefit of having the wetting contact to wavelength ratio to be larger than the constant of 0.2 found in experimental studies. The CHF regime can occur by a limitation of the stacks to have access to the liquid phase, as it happens when they are completely submerged in a vapor phase, or by reaching the maximum capillary pressure drop in the stack (as per the Darcy–Ergun momentum equation), or by reaching an entrainment limit of the vapor flow passed the capillary columns. Therefore the critical heat flux can also be extended as long as the capillary columns protrude over the vapor layer and their viscous capillary and entrainment limits are not reached.     

An experimental study of void fraction and heat transfer under upward and downward flow boiling conditions

Heat transfer coefficient and actual void fraction have been measured during upflow and downflow boiling of water in an annular channel. At the same values of pressure, mass flux, heat flux and flow quality significant difference of void fraction has been established in upflow and downflow. The upflow and downflow heat transfer coefficients did not deviate significantly from each other, if compared at identical values of pressure, mass flux, heat flux and actual void fraction.     

Effects of carbon nanotube coating on flow boiling in a micro-channel

Experiments were performed to assess the heat transfer enhancement benefits of coating the bottom wall of a shallow rectangular micro-channel with carbon nanotubes (CNTs). Using water as working fluid, tests were performed with a bare copper surface and three separate, yet identical CNT-coated surfaces. Each of the CNT-coated surfaces was tested repeatedly at the same mass velocity to explore any time dependence of heat transfer performance parameters, especially critical heat flux (CHF). Appreciable differences in the influence of CNT coating were observed at high mass velocities as compared to low. CHF was repeatable at low mass velocities but degraded following repeated tests at high mass velocities, proving high flow velocities cause appreciable changes to the morphology of the CNT-coated surface. SEM images show the initially near-vertical CNTs were bent upon the heated surface at high mass velocities to form a repeated ‘fish-scale’ pattern. Voids between the ‘fish scales’ provided near-zero-angle cavities that enhanced heat transfer in the nucleate boiling region compared to the bare copper surface. While CHF was enhanced by the increased heat transfer area associated with the CNT coating, the enhancement decreased following repeated tests as the CNT fin effect was compromised by the bending.     

Assessment of dimensionless CHF correlations for subcooled flow boiling in microgravity and Earth gravity

A comprehensive review and analysis of prior subcooled flow boiling CHF correlations was conducted to identify those correlations that provide the most accurate predictions for dielectric working fluids and small rectangular flow passages found in electronics cooling applications in both microgravity and Earth gravity. Since most prior correlations were derived from water databases, only those with dimensionless form were deemed potentially suitable for other working fluids. Only a small fraction of these dimensionless correlations were found to tackle other fluids and more complicated flow and heating configurations with acceptable accuracy. These correlations were ranked relative to mean error, mean absolute error, and root mean square error. Better predictions where achieved when correlations were based on the heated diameter rather than the hydraulic diameter because of the ability of the former to better describe vapor development in subcooled flow. Two previous correlations by Hall and Mudawar provided the best overall CHF predictions for both microgravity and Earth gravity.     

Flow boiling heat transfer in the evaporator of a loop thermosyphon operating with CuO based aqueous nanofluid

An experimental study was carried out to understand the flow boiling heat transfer of water based CuO nanofluids in the evaporator of a thermosyphon loop under steady sub-atmospheric pressures. Experimental results show that both the heat transfer coefficient (HTC) and the critical heat flux (CHF) of flow boiling in the evaporator of the thermosyphon loop could be enhanced by substituting nanofluids for water. The operating pressure has apparent impact on the HTC enhancement of nanofluids. However, the operating pressure has negligible effect on the CHF enhancement. There exists an optimal mass concentration of nanoparticles corresponding to the best enhancement effect. Experimental results show that the CHF enhancement results mainly from the existing of the coating layer on the heated surface formed by the sediment of nanoparticles. However, the HTC enhancement results from the effects of both the existing of the coating layer and the change of thermophysical properties of the working fluid.     

Critical heat flux in subcooled flow boiling with water in a tube with axially nonuniform heating

Critical heat flux (CHF) in subcooled flow boiling under axially nonuniform heating conditions was experimentally investigated using a tube heated with a dc power source. The thickness of the tube wall in the axial direction was varied to attain axially nonuniform heating. The different thicknesses, therefore, separated the tube into regions of high heat flux and regions of low heat flux. The lengths of these regions of the tube were also varied to study the effect on the CHF. The objective of this system is to initiate boiling in the high-heat-flux region, thus increasing heat transfer, and to interrupt the bubble boundary layer in the low-heat-flux region. Because it is the initiation of boiling that increases heat transfer, the performance of such a system is linked to its effectiveness in repeatedly interrupting and re-establishing the bubble boundary layer. Our experiments, involving tubes that had sections of different thicknesses and different lengths, showed that when the heat flux in the low-heat-flux region was below the net vapor generation (NVG) heat flux, this system enhanced the CHF, but not when it was above the NVG. Also, for relatively short low-heat-flux regions, the CHF was not enhanced, presumably because there was insufficient time to interrupt the bubble boundary layer. © 1998 Scripta Technica, Heat Trans Jpn Res, 27(2): 169–178, 1998     

Heat transfer characteristics of submerged jet impingement boiling of saturated FC-72

Global heat transfer characteristics of submerged jet impingement boiling of a highly wetting dielectric fluid (FC-72) on a heated copper surface are presented. The effect of variation of the jet exit Reynolds number (Re) on boiling incipience, fully developed nucleate boiling, and critical heat flux (CHF) are documented. The jet exit Re is varied by variations of the jet exit velocity and the jet nozzle diameter for a fixed surface diameter. High-speed visualization is used to supplement trends observed in the heat transfer data. Scenarios of low and high incipience wall superheat are identified, corresponding to partially or fully developed nucleate boiling condition upon initiation of boiling. For the high incipience wall superheat scenario, the time of spread of boiling activity over the heated surface during temperature overshoot is found to be inversely proportional to the wall superheat temperature at boiling incipience. The incipient boiling wall superheat temperature is found to be uncorrelated with jet Re and jet diameter. A cumulative probability distribution function is used to characterize the onset of boiling with wall superheat temperature. At a fixed Re, CHF increases with increasing jet velocity and with decreasing jet diameter, indicating that the jet kinetic energy is a key parameter in CHF enhancement. The CHF data are compared with available jet impingement CHF correlations from literature on free surface and confined jets. The free surface jet CHF correlation by Monde and Katto (1978) [1] is seen to best capture the experimental data trends for Re greater than 4000.     

An Experimental Investigation of Nucleate Pool Boiling Heat Transfer of Nanofluids From a Hemispherical Surface

An experimental investigation of nucleate pool boiling heat transfer is carried out using SiO₂ nanofluid in atmospheric pressure and saturated conditions. The results show that the nucleate boiling heat transfer coefficient (HTC) of the nanofluids is lower than that of deionized water, especially in high heat fluxes. In addition, the experimental results indicate that the critical heat flux (CHF) improves up to 45% with the increase of the nanoparticle volume concentration. Atomic force microscopy images from the boiling surface reveal that the nanoparticles are deposited on the heating surface during the nanofluid pool boiling experiments. It is found that the boiling HTC deteriorates as a result of the reduction in active nucleation sites and the formation of extra thermal resistance due to blocked vapor in the porous structures near the heating surface. Furthermore, the improvement of the surface wettability causes an increase in CHF. Based on the experimental investigations, it can be concluded that the changes in the properties of the boiling surface are mainly responsible for the variations in nanofluids boiling performance.     

Marangoni effects on the boiling of 2-propanol/water mixtures in a confined space

In this study, boiling experiments were conducted with 2-propanol/water mixtures in a confined gap under various gravity levels to examine the Marangoni effects on near-bubble microscale transport. Full boiling curves were obtained and two boiling regimes determined--nucleate and pseudo film boiling. The transition condition and the critical heat flux were also identified. Relative to pool boiling, the gap geometry caused lower CHF values, and deteriorated heat transfer at high superheated temperatures. This influence was particularly significant when greater Marangoni forces were present under reduced gravity conditions. The results of this study demonstrate the complex interaction that these three factors--Marangoni force, gravity level, and gap size--have on heat transfer.     

Effect of nanoparticles on CHF enhancement in pool boiling of nano-fluids

To investigate the characteristics of CHF (Critical Heat Flux) enhancement using nano-fluids, pool boiling CHF experiments of two water-based nano-fluids with titania and alumina nanoparticles were performed using electrically heated metal wires under atmospheric pressure. The results showed that the water-based nano-fluids significantly enhanced CHF compared to that of pure water. SEM (Scanning Electron Microscopy) observation subsequent to the pool boiling experiments revealed that a lot of nanoparticles were deposited on heating surface during pool boiling of nano-fluids. In order to investigate the role of the nanoparticle surface coating on CHF enhancement of nano-fluids, pool boiling CHF of pure water was measured using a nanoparticle-coated heater prepared by pool boiling of nano-fluids on a bare heater. It was found that pool boiling of pure water on the naonoparticle-coated heater sufficiently achieved the CHF enhancement of nano-fluids. It is supposed that CHF enhancement in pool boiling of nano-fluids is mainly caused by the nanoparticle coating of the heating surface.     

Critical heat flux of natural circulation boiling in a vertical tube: Effect of oscillation and circulation on CHF

An experimental study has been made to elucidate an effect of oscillated flow induced near critical heat flux (CHF) and natural circulated flow of vapor and liquid in a vertical tube on the CHF. The experiment has been carried out for the condition of heated tube length of L=100-1000 mm, tube diameter of D=4-9 mm and the CHF is measured under the condition that the exit of the unheated tube connecting the heated tube is extruded into a vapor chamber to prevent a liquid flowing into the heated tube from the top. The experiment reveals that the CHF for D=7 and 9 mm and any tube length from 100 to 1000 mm becomes identical to that for the case of the tube top in the liquid, while the CHF for D=4 and 5 mm is smaller than that for the case of the tube top in the liquid due to no liquid supply from the top. It is found that the oscillation induced near the CHF increases the CHF.     

CHF model for subcooled flow boiling in Earth gravity and microgravity

This study is the first attempt at extending the Interfacial Lift-off CHF Model to subcooled flow boiling conditions. A new CHF database was generated for FC-72 from ground tests as well as from microgravity tests that were performed in parabolic flight trajectory. These tests also included high-speed video imaging and analysis of the liquid–vapor interface during the CHF transient. Both the CHF data and the video records played a vital role in constructing and validating the extended CHF model. The fundamental difference between the original Interfacial Lift-off Model, which was developed for saturated flow boiling, and the newly extended model is the partitioning of wall energy between sensible and latent heat for subcooled flow boiling. This partitioning is modeled with the aid of a new “heat utility ratio”. Using this ratio, the extended Interfacial Lift-off Model is shown to effectively predict both saturated and subcooled flow boiling CHF in Earth gravity and in microgravity.