Convective boiling heat transfer characteristics of CO2 in microchannels

Convective boiling heat transfer coefficients and dryout phenomena of CO₂ are investigated in rectangular microchannels whose hydraulic diameters range from 1.08 to 1.54 mm. The tests are conducted by varying the mass flux of CO₂ from 200 to 400 kg/m² s, heat flux from 10 to 20 kW/m², while maintaining saturation temperature at 0, 5 and 10 °C. Test results show that the average heat transfer coefficient of CO₂ is 53% higher than that of R134a. The effects of heat flux on the heat transfer coefficient are much significant than those of mass flux. As the mass flux increases, dryout becomes more pronounced. As the hydraulic diameter decreases from 1.54 to 1.27 mm and from 1.27 to 1.08 mm at a heat flux of 15 kW/m² and a mass flux of 300 kg/m² s, the heat transfer coefficients increase by 5% and 31%, respectively. Based on the comparison of the data from the existing models with the present data, the Cooper model and the Gorenflo model yield relatively good predictions of the measured data with mean deviations between predicted and measured data of 21.7% and 21.2%, respectively.     

Bubble dynamics in microchannels. Part II: two parallel microchannels

The present work investigates experimentally the bubble dynamics in two parallel trapezoidal microchannels with a hydraulic diameter of 47.7 μm for both channels. The fabrication process of the two parallel microchannels employs a silicon bulk micromachining and anodic bounding process. The results of this study demonstrate that the bubble growth and departure is generally similar to that in a single microchannel, i.e., bubbles, in general, grow linearly with time and their departure is governed by surface tension and drag due to bulk two-phase flow. For the two low mass flow rates, the growth of bubble in slug flow is also investigated. It is found that the bubble grows in the axial direction both forward and backward with its length increases exponentially due to evaporation of the thin liquid film between the bubble and heating wall. However, the coefficient of exponent is much smaller than that caused by evaporation due to the limitation effect of liquid pressure around the bubble.     

An experimental study of flow boiling instability in a single microchannel

A simultaneous visualization and measurement study has been carried out to investigate stable and unstable flow boiling phenomena of deionized water in a single microchannel having a hydraulic diameter of 155 µm with a bottom Pyrex glass wall. Fifteen platinum serpentine microheaters, bonded on the Pyrex glass wall, were used to measure local instantaneous wall temperatures. At low mass flux, a syringe pump was used to drive the subcooled water passing through the microchannel. Stable and unstable flow boiling modes in the single microchannel are identified, and flow pattern maps in terms of heat flux and mass flux as well as in term of exit vapor quality are presented respectively. It was found that unstable flow boiling occurred in the single microchannel if the exit vapor quality x_e > 0.013.     

An experimental study of convective heat transfer in silicon microchannels with different surface conditions

An experimental investigation has been performed on the laminar convective heat transfer and pressure drop of water in 13 different trapezoidal silicon microchannels. It is found that the values of Nusselt number and apparent friction constant depend greatly on different geometric parameters. The laminar Nusselt number and apparent friction constant increase with the increase of surface roughness and surface hydrophilic property. These increases become more obvious at larger Reynolds numbers. The experimental results also show that the Nusselt number increases almost linearly with the Reynolds number at low Reynolds numbers (Re<100), but increases slowly at a Reynolds number greater than 100. Based on 168 experimental data points, dimensionless correlations for the Nusselt number and the apparent friction constant are obtained for the flow of water in trapezoidal microchannels having different geometric parameters, surface roughnesses and surface hydrophilic properties. Finally, an evaluation of heat flux per pumping power and per temperature difference is given for the microchannels used in this experiment.     

Numerical computation of fluid flow and heat transfer in microchannels

Three-dimensional fluid flow and heat transfer phenomena inside heated microchannels is investigated. The steady, laminar flow and heat transfer equations are solved using a finite-volume method. The numerical procedure is validated by comparing the predicted local thermal resistances with available experimental data. The friction factor is also predicted in this study. It was found that the heat input lowers the frictional losses, particularly at lower Reynolds numbers. At lower Reynolds numbers the temperature of the water increases, leading to a decrease in the viscosity and hence smaller frictional losses.     

Prediction of the onset of nucleate boiling in microchannel flow

The onset of nucleate boiling in the flow of water through a microchannel heat sink was investigated. The microchannels considered were 275 μm wide by 636 μm deep. Onset of nucleate boiling was identified with a high-speed imaging system and the heat flux at incipience was measured under various flow conditions. An analytical model was developed to predict the incipient heat flux as well as the bubble size at the onset of boiling. The closed-form solution obtained sheds light on the impact of the important system parameters on the incipient heat flux. The model predictions yield good agreement with the experimental data.     

Flow boiling in microchannels and microgravity

A critical review of the state of the art of research on internal forced convection boiling in microchannels and in microgravity conditions is the main object of the present paper.     

Visualization of a principle mechanism of critical heat flux in pool boiling

A new experimental work was made to discover a principle mechanism of the burnout in pool boiling. Here, we directly observed a liquid layer structure under a massive vapor clot and the liquid layer-related burnout phenomenon. Based on the present observations, we have made a visual model for the formation and dryout of a liquid film under its vapor environment. At the formation process, liquid is trapped in interleaved space between growing bubbles and surface and the liquid trapping continues between coalesced bubbles and surface. In the dryout process, we especially observed vapor “holes” made by spontaneous breakup of discrete nucleating bubbles inside a vapor clot. The burnout can be triggered by the evaporation of the liquid film region expanded from rims of the holes.     

Condensation flow patterns in silicon microchannels

A simultaneous visualization and measurement experiment was carried out to investigate condensation flow patterns of steam flowing through an array of trapezoidal silicon microchannels, having a hydraulic diameter of 82.8 μm and a length of 30 mm. The degassed and deionized water steam flowing in the microchannels was cooled by flowing water of 8 °C from the bottom. The silicon microchannels were covered with a thin transparent pyrex glass from the top which enabled the visualization of flow patterns. Experiments were performed at different inlet pressures ranging from 4.15 × 10⁵ Pa to 1.25 × 10⁵ Pa (with corresponding mass fluxes decreasing from 47.5 g/cm² s to 19.3 g/cm² s) while the outlet pressure was maintained at a value of 10⁵ Pa. Different condensation flow patterns such as fully droplet flow, droplet/annular/injection/slug-bubbly flow, annular/injection/slug-bubbly flow, and fully slug-bubbly flow were observed in the microchannels. At a given inlet pressure and mass flux, the flow pattern depended on both the location and time. Of particular interest is that the vapor injection flow, consisting of a series of bubble growth and detachment activities, appeared and disappeared periodically. During the disappearance period of injection flow, the slug-bubbly flow at downstream changed to the single-phase liquid flow due to the reversed flow of outlet condensate, while the annular flow at upstream changed to the vapor flow due to the effect of incoming vapor. Therefore, two-phase flow and single-phase flow appeared alternatively in the microchannels, causing large fluctuations of wall temperatures as well as other measurements. It was also found that the occurrence of vapor injection flow moved from the outlet toward the inlet as the mass flux was decreased. The vapor injection flow and its induced condensation instabilities in microchannels are reported here for the first time.     

Experimental study of radiation absorption by microchannels of varying aspect ratios

A linear solar concentrator produces electricity by using a mirror to focus sunlight on a fluid filled tube known as a heat collection element. The fluid inside the element is then used as a heat source for steam generation in a conventional steam turbine power plant. This study examined the effect of adding microstructures to the surface of a heat collection element to improve system efficiency. Four test pieces, one with a smooth surface and three with a microstructured surface were compared experimentally for a given energy input and five different flow rates ranging from 0.84 cm³/s to 2.5 cm³/s. Over the entire range of flow rates the microchannel test piece absorbed no less than 1.29 times the energy of the smooth test piece.     

Bubble dynamics in microchannels. Part I: single microchannel

The present work explores experimentally bubble dynamics in a single trapezoid microchannel with a hydraulic diameter of 41.3 μm. The fabrication process of the microchannel employs a silicon bulk micromachining and anodic bounding process. Bubble nucleation, growth, departure size, and frequency are observed using a high speed digital camera and analyzed by the Image-Pro. The results of the study indicates that the bubble nucleation in the microchannel may be predicted from the classical model with microsized cavities and the bubble typically grows with a constant rate from 0.13 to 7.08 μm/ms. Some cases demonstrate an extraordinarily high growth rate from 72.8 to 95.2 μm/ms. The size of bubble departure from the microchannel wall is found to be governed by surface tension and drag of bulk flow and may be fairly correlated by a modified form of Levy equation. The bubble frequency in the microchannel is comparable to that in an ordinary sized channel. The traditional form of frequency-departure-diameter relationship seems to be inexistent in the microchannel of this study.     

Enhancement of boiling heat transfer in a 5 × 3 tube bundle

The results of an experimental investigation on nucleate boiling heat transfer in an electrically heated 5 × 3 in-line horizontal tube bundle under pool and low cross-flow conditions of saturated water near atmospheric pressure are presented here. It is observed that the heat transfer coefficient is minimum on bottom row tubes and increases in the upward direction with maximum values on top row tubes. Also, heat transfer coefficient on central column tubes was found to be slightly higher than those on the corresponding side tubes. Further, a Chen-type relation has been used to determine the local boiling heat transfer coefficient on a tube in a heated tube bundle.     

Pool boiling characteristics of nano-fluids

Common fluids with particles of the order of nanometers in size are termed as ‘nano-fluids’ which have created considerable interest in recent times for their improved heat transfer capabilities. With very small volume fraction of such particles the thermal conductivity and convective heat transfer capability of these suspensions are significantly enhanced without the problems encountered in common slurries such as clogging, erosion, sedimentation and increase in pressure drop. This naturally brings out the question whether such fluids can be used for two phase applications or in other words phase change in such suspensions will be assistant or detrimental to the process of heat transfer. The present paper investigates into this question through experimental study of pool boiling in water-Al₂O₃ nano-fluids. The results indicate that the nano-particles have pronounced and significant influence on the boiling process deteriorating the boiling characteristics of the fluid. It has been observed that with increasing particle concentration, the degradation in boiling performance takes place which increases the heating surface temperature. This indicates that the role of transient conduction in pool boiling is overshadowed by some other effect. Since the particles under consideration are one to two orders of magnitude smaller than the surface roughness it was concluded that the change of surface characteristics during boiling due to trapped particles on the surface is the cause for the shift of the boiling characteristics in the negative direction. The results serve as a guidance for the design of cooling systems with nano-fluids where an overheating may occur if saturation temperature is attained. It also indicates the possibility of such engineered fluids to be used in material processing or heat treatment applications where a higher pre-assigned surface temperature is required to be maintained without changing the fluid temperature.     

Effects of fin geometry on boiling heat transfer from silicon chips with micro-pin-fins immersed in FC-72

Experiments were performed to study the effects of the height and thickness of square micro-pin-fin on boiling heat transfer from silicon chips immersed in a pool of degassed or gas-dissolved FC-72. Six kinds of micro-pin-fins with the dimensions of 30 × 60, 30 × 120, 30 × 200, 50 × 60, 50 × 200 and 50 × 270 μm² (thickness, t × height, h) were fabricated on the surface of a square silicon chip with the dimensions of 10 × 10 × 0.5 mm³ by using the dry etching technique. The fin pitch was twice the fin thickness. The experiments were conducted at the liquid subcooling, ΔT_sub, of 0, 3, 25 and 45 K under the atmospheric condition. The results were compared with previous results for a smooth chip and three chips with enhanced heat transfer surfaces. The micro-pin-finned chips showed a considerable heat transfer enhancement in the nucleate boiling region and increase in the critical heat flux, q_CHF, as compared to the smooth chip. The wall temperature at the CHF point was always less than the maximum allowable temperature for LSI chips (=85 °C). For a fixed value of t, q_CHF increased monotonically with increasing h. The increase was more significant for larger t. The q_CHF increased almost linearly with increasing ΔT_sub. The maximum value of allowable heat flux (=84.5 W/cm²), 4.2 times as large as that for the smooth chip, was obtained by the chip with h=270 μm and t=50 μm at ΔT_sub=45 K.     

Experimental investigations of flow boiling heat transfer and pressure drop in straight and expanding microchannels – A comparative study

Flow boiling experiments were conducted in straight and expanding microchannels with similar dimensions and operating conditions. Deionized water was used as the coolant. The test vehicles were made from copper with a footprint area of 25 mm × 25 mm. Microchannels having nominal width of 300 μm and a nominal aspect ratio of 4 were formed by wire cut Electro Discharge Machining process. The measured surface roughness (Ra) was about 2.0 μm. To facilitate easier comparison with the straight microchannels and also to simplify the method of fabrication, the expanding channels were formed with the removal of fins at selected location from the straight microchannel design, instead of using a diverging channel. Tests were performed on both the microchannels over a range of mass fluxes, heat fluxes and an inlet temperature of 90 °C. It was observed that the two-phase pressure drop across the expanding microchannel heat sink was significantly lower as compared to its straight counterpart. The pressure drop and wall temperature fluctuations were seen reduced in the expanding microchannel heat sink. It was also noted that the expanding microchannel heat sink had a better heat transfer performance than the straight microchannel heat sink, under similar operating conditions. This phenomenon in expanding microchannel heat sink, which was observed in spite of it having a lower convective heat transfer area, is explained based on its improved flow boiling stability that reduces the pressure drop oscillations, temperature oscillations and hence partial dry out.     

Visualization of flow patterns and bubble behavior during flow boiling in open microchannels

Flow boiling in microchannels is favored by the heat transfer community due to the high heat transfer rates that can be obtained with lower mass flow rates. However, the heat transfer rates for flow boiling in microchannels are impacted by flow reversals and flow instabilities. An open microchannel structure was recently proposed to reduce the impact of the flow boiling instabilities. Subcooled flow boiling experiments were conducted in open microchannels using deionized water. The open microchannels had 6 parallel channels with a 0.3 mm uniform thickness gap above them The channels were fabricated on a 6 mm × 40 mm copper block. The channels were 0.5 mm wide and 0.3 mm deep with 0.43 mm wide fins between them. Flow visualizations were performed with a high-speed CCD camera with the results showing that the flow regimes in the open microchannels differ from those in closed microchannels with stratified flow and no flow instability. Two types of confined bubbles were observed with characterizations of the effects of the bubbles on each other. The heat transfer mechanisms for flow boiling in open microchannels are also described.     

Visualization study of steam condensation in wide rectangular silicon microchannels

A visualization study is conducted to investigate condensation flow in wide rectangular silicon microchannels with the hydraulic diameter of 90.6 μm and width/depth ratio of 9.668. Droplet-annular compound flow, injection flow, and vapor slug-bubbly flow are observed along the channel, which differ from that in other cross-sectional shape microchannels. In the droplet-annular compound flow region, the vertical walls (short side) of the channel are completely covered by the condensate, while droplet condensation still exists on the horizontal wall (long side) of the channel. The location of the injection flow will be postponed with the increasing inlet vapor Reynolds number. The injection frequency will increase with the increasing inlet vapor Reynolds number and condensate Weber number. More specifically, the frequency in the wide rectangular microchannels is lower than that in triangular microchannels having the same hydraulic diameter. It is confirmed that the cross-sectional shape of the microchannel plays a significant role on the instability of condensation flow. In addition, the correlation of Nusselt number is also presented.     

Visualization study of steam condensation in triangular microchannels

A visualization experiment is conducted to investigate the condensation of steam in a series of triangular silicon microchannels. The results indicate that droplet, annular, injection and slug-bubbly flow are the dominant flow patterns in these triangular silicon microchannels. With increased mass flow rate, or an increase in the hydraulic diameter under the same Reynolds number, the location at which the injection occurred is observed to move towards the channel outlet. The frequency of the injection increases, i.e. the flow of condensation instability is higher with increased inlet vapor Reynolds number, condensate Weber number and the prolongation of the injection location, or with a decrease in the hydraulic diameter of the channel. In addition, the wall temperature of the channel decreases along the condensation stream. The total pressure drop, the average condensation heat transfer coefficient and the average Nusselt number are observed to be larger with increased inlet vapor Reynolds number. Moreover, it is found that the condensation heat transfer is enhanced by a reduction in the channel scale.     

Visualization of convective boiling heat transfer in single microchannels with different shaped cross-sections

Convective boiling in transparent single microchannels with similar hydraulic diameters but different shaped cross-sections was visualized, along with simultaneous measurement of the local heat transfer coefficient. Two types of microchannels were tested: a circular Pyrex glass microtube (210 μm inner diameter) and a square Pyrex glass microchannel (214 μm hydraulic diameter). A 100-nm-thick semi-transparent ITO/Ag thin film sputtered on the outer wall of the microchannel was used for direct joule heating of the microchannel.The flow field visualization showed semi-periodic variation in the flow patterns in both the square and circular microchannels. Such variation was because the confined space limited the bubble growth in the radial direction.In the square microchannel, both the number of nucleation bubbles and the local heat transfer coefficient increased with decreasing vapor quality. The corners acted as active nucleation cavities, leading to the higher local heat transfer coefficient. In contrast, lack of cavities in the smooth glass circular microchannel yielded a relatively smaller heat transfer coefficient at lower vapor quality. Finally, the heat transfer coefficient was higher for the square microchannel because corners in the square microchannel acted as effective active nucleation sites.     

Convective boiling heat transfer and two-phase flow characteristics inside a small horizontal helically coiled tubing once-through steam generator

The pressure drop and boiling heat transfer characteristics of steam-water two-phase flow were studied in a small horizontal helically coiled tubing once-through steam generator. The generator was constructed of a 9-mm ID 1Cr18Ni9Ti stainless steel tube with 292-mm coil diameter and 30-mm pitch. Experiments were performed in a range of steam qualities up to 0.95, system pressure 0.5-3.5 MPa, mass flux 236-943 kg/m²s and heat flux 0-900 kW/m². A new two-phase frictional pressure drop correlation was obtained from the experimental data using Chisholm’s B-coefficient method. The boiling heat transfer was found to be dependent on both of mass flux and heat flux. This implies that both the nucleation mechanism and the convection mechanism have the same importance to forced convective boiling heat transfer in a small horizontal helically coiled tube over the full range of steam qualities (pre-critical heat flux qualities of 0.1-0.9), which is different from the situations in larger helically coiled tube where the convection mechanism dominates at qualities typically >0.1. Traditional single parameter Lockhart-Martinelli type correlations failed to satisfactorily correlate present experimental data, and in this paper a new flow boiling heat transfer correlation was proposed to better correlate the experimental data.