Studies on pool boiling heat transfer: Macrolayer thickness in transition boiling

Macrolayer thicknesses in transition boiling were determined from the energy balance relation q_tr = ρ_lH_fgδ_l·f , based on measurements of q_tr (the time-averaged heat flux in transition boiling) and f (the detachment frequency of vapor masses) for water and ethanol boiling on vertical and horizontal 15-mm-diameter surfaces under atmospheric pressure. The macrolayer thickness for the vertical surface, designed to prevent liquid contact with the periphery of the surface during the vapor mass hovering, agreed well with the correlation proposed previously by the present authors, when the heat flux at macrolayer formation is obtained from a nucleate boiling curve extrapolated to the superheat of transition boiling. The macrolayer on the horizontal surface was apparently thickened due to the inflow of bulk liquid beneath the growing vapor masses. © 1999 Scripta Technica, Heat Trans Jpn Res, 27(8): 568–583, 1998     

Contribution of thin-film evaporation during flow boiling inside microchannels

Flow boiling through microchannels is characterized by nucleation and growth of vapor bubbles that fill the entire channel cross-sectional area. As the bubbles nucleate and grow inside the microchannel, a thin film of liquid or a microlayer gets trapped between the bubbles and the channel walls. The heat transfer mechanism present at the channel walls during flow boiling is studied numerically. It is then compared to the heat transfer mechanisms present during nucleate pool boiling and in a moving evaporating meniscus. Increasing contact angle improved wall heat transfer in case of nucleate boiling and moving evaporating meniscus but not in the case of flow boiling inside a microchannel. It is shown that the thermal and the flow fields present inside the microchannel around a bubble are fundamentally different as compared to nucleate pool boiling or in a moving evaporating meniscus. It is explained why thin-film evaporation is the dominant heat transfer mechanism and is responsible for creating an apparent nucleate boiling effect inside a microchannel.     

Direct numerical simulations of pool boiling curves including heater's thermal responses and the effect of vapor phase's thermal conductivity

Effects of heater's thermal properties and vapor phase's thermal conductivity on saturated pool boiling above a large horizontal heater are simulated numerically based on an improved pseudo-potential liquid-vapor phase change lattice Boltzmann model. A transient conjugate heat transfer problem is under consideration, where the conjugate thermal boundary condition is imposed and heater's thermal responses during boiling processes are investigated. Saturated pool boiling curves from onset of nucleate boiling to critical heat flux (CHF), to transition boiling regime to stable film boiling regime are obtained numerically. It is found that the simulated critical heat flux (CHF) agrees reasonably well with existing analytical models. Also, the simulated boiling heat fluxes in stable film boiling regime are shown to be in good agreement with the existing analytical solution. Thus, this improved pseudo-potential liquid-vapor phase change lattice Boltzmann model is quantitatively validated. Simulation results demonstrate that there is significant maldistribution in temperature distribution near the top of heater surface in nucleate boiling regime, CHF point and transition boiling regime. As a result, two-dimensional heat conduction can not be ignored when evaluating heat flux closely beneath the heater's top surface. It is also shown that both heater's thermal conductivity and thermal mass (the product of density and specific heat at constant pressure) have no effect on CHF value as well as the boiling curve in nucleate boiling regime and film boiling regime for a thick heater. However, the transition boiling regime of the boiling curve moves to the left with the increasing heater thermal conductivity and heater thermal mass for a thick heater. Increasing the vapor theraml conductivity has no effect on CHF but would increase boiling heat flux in film boiling regime, and hence shortening the transition boiling regime.     

Macrolayer formation and mechanisms of nucleate boiling,critical heat flux,and transition boiling

The drying process of a macrolayer on a 15 mm diameter boiling surface was observed with high speed video in the region of nucleate and of transition boiling close to the critical heat flux (CHF). It was found that the macrolayer rests beneath a large vapor mass. It partially dries in nucleate boiling and completely dries in transition boiling at the detachment of the vapor mass. The macrolayer thickness at CHF and in transition boiling was determined on the basis of the energy balance relation proposed by Katto and Yokoya. The macrolayer thickness at low heat flux was obtained by decreasing CHF with downward-facing heating surfaces and agreed well with the correlation proposed previously by the present authors. The macrolayer thickness in transition boiling with a vertical surface also agrees fairly well with the correlation, when the heat flux at macrolayer formation, given on the nucleate boiling curve, is extrapolated to surface superheat of transition boiling and when the surface temperature at macrolayer formation is equal to a time-averaged value. © 1998 Scripta Technical, Heat Trans Jpn Res, 27(2): 155–168, 1998     

Measurement of surface dryout near heating surface at high heat fluxes in subcooled pool boiling

The authors have conducted measurements of liquid–vapor behavior in the vicinity of a heating surface for saturated and subcooled pool boiling on an upward-facing copper surface by using a conductance probe method. A previous paper [A. Ono, H. Sakashita, Liquid–vapor structure near heating surface at high heat flux in subcooled pool boiling, Int. J. Heat Mass Transfer 50 (2007) 3481–3489] reported that thicknesses of a liquid rich layer (a so-called macrolayer) forming in subcooled boiling are comparable to or thicker than those formed near the critical heat flux (CHF) in saturated boiling. This paper examines the dryout behavior of the heating surface by utilizing the feature that a thin conductance probe placed very close to the heating surface can detect the formation and dryout of the macrolayer. It was found that the dryout of the macrolayer formed beneath a vapor mass occurs in the latter half of the hovering period of the vapor mass. Two-dimensional measurements conducted at 121 grid points in a 1-mm × 1-mm area at the center of the heating surface showed that the dryout commences at specific areas and spreads over the heating surface as the heat flux approaches the CHF. Furthermore, transient measurements of wall void fractions from nucleate boiling to transition boiling were conducted under the transient heating mode, showing that the wall void fraction has small values (<10%) in the nucleate boiling region, and then steeply increases in the transition boiling region. These findings strongly suggest that the macrolayer dryout model is the most appropriate model of the CHF for saturated and subcooled pool boiling of water on upward facing copper surfaces.     

Effect of salt additives on film boiling heat transfer and mechanism of quenching temperature rise

A high‐temperature stainless‐steel sphere was immersed into various salt solutions to investigate the film boiling behavior at vapor film collapse. The film boiling behavior around the sphere was observed with a digital video camera. Both surface temperature of the sphere and solid–liquid contact behavior were measured. Results of the experiment showed that salt additives enhanced condensation heat transfer, and the observed vapor film was thinner. Furthermore, the frequency of direct contact between the sphere surface and coolant increased. The quenching temperature increased with increased salt concentration, and was highly correlated with ion molar concentration, which represents the density of ions regardless of the type of salt. © 2010 Wiley Periodicals, Inc. Heat Trans Asian Res; Published online in Wiley Online Library ( wileyonlinelibrary.com ). DOI 10.1002/htj.20327     

Molecular dynamics study of wettability and pitch effects on maximum critical heat flux in evaporation and pool boiling heat transfer

Molecular dynamics simulations were employed to investigate the effects of wettability (contact angle) and pitch on nanoscale evaporation and pool boiling heat transfer of a liquid argon thin film on a horizontal copper substrate topped with cubic nano-pillars. The liquid–solid potential was incrementally altered to vary the contact angle between hydrophilic (～0°) and hydrophobic (～127°), and the pitch (distance between nano-pillars) was varied between 21.7 and 106.6?Å to observe the resultant effect on boiling heat transfer enhancement. For each contact angle, the superheat was gradually increased to initiate nucleate boiling and eventually pass the critical heat flux (CHF) into the film boiling regime. The CHF increases with pitch, and tends to decrease substantially with increasing contact angle. A maximum overall heat flux of 1.59?×?10⁸?W/m² occurs at the largest pitch investigated (106.6?Å), and as the contact angle increases the superheat required to reach the CHF condition also increases. Finally, in certain cases of small pitch and large contact angle, the liquid film was seen to transition to a Cassie–Baxter state, which greatly hindered heat transfer.     

Examination of minimum-heat-flux-point condition for film boiling on a sphere in terms of the limiting liquid superheat and the critical vapor film thickness

Previously proposed theories of the minimum-heat-flux-point (MHF-point) condition were examined using available experimental data obtained from the immersion cooling of spheres in water. The sphere diameter ranged from 9.5 to 30 mm and the liquid subcooling from 0 to 85 K. The limiting liquid superheat predicted by the Lienhard equation was compared with the liquid–solid interface superheat at the instant of liquid–solid contact at the MHF-point. The results showed that the liquid–solid interface superheat was not limited by the limiting liquid superheat and its value was connected with the collapse mode of vapor film. The collapse mode was a coherent collapse at a low interface superheat and the mode changed to a propagative collapse as the interface superheat increased. The critical vapor film thickness obtained from the linear stability analysis of vapor film was compared with the calculated value of average vapor film thickness at the MHF-point. For all data, the ratio of the average vapor film thickness to the critical vapor film thickness was correlated well as a function of liquid subcooling. The ratio decreased with increasing liquid subcooling and tended to about 0.8 to 1 depending on the experiments. This indicated that the MHF-point at a high liquid subcooling was determined by the critical vapor film thickness. A physical consideration was given to the effect of liquid–solid contact that occurred in the film boiling region on the calculated value of the vapor film thickness and the stability of vapor film.     

Boiling Feature on a Super Water-Repellent Surface

The boiling feature on a super water-repellent (SWR) surface has been studied. The SWR surface has a coating layer of fine particles of nickel and PTFE. Its contact angle to water is 152°in room temperature. The heat transfer surface is facing upward, and the diameter of the heated section is 17 mm. The boiling feature of this surface is completely different from that of usual surfaces. The stable film boiling occurs in very small superheating, and there is no nucleate boiling region. The bubbles generated on the surface coalesce into a vapor film without departing from the surface. The stable vapor film exists even at a surface temperature below the saturation temperature.     

Statistic analysis of the boiling curve for a droplet

Statistic analysis of the experimentally determined values of a water droplet's evaporation times was made. Measurements were taken from heating surface temperatures characteristic for liquid phase natural convection up to film boiling of a droplet. The results obtained confirm the hypothesis of two boiling curves in the region of transition boiling proposed by Witte and Lienhard. They also allow this concept on the region of nucleate boiling to be expanded.     

Heat transfer in subcooled jet impingement boiling at high wall temperatures

An analytical approach for heat transfer modelling of jet impingement boiling is presented. High heat fluxes with values larger than 10 MW/m² can be observed in the stagnation region of an impinging jet on a red hot steel plate with wall temperatures normally being associated with film boiling. However, sufficiently high degrees of subcooling and jet velocity prevent the formation of a vapor film, even if the wall superheat is large. Heat transfer is governed by turbulent diffusion caused by the rapid growth and condensation of vapor bubbles. Due to the high population of bubbles at high heat fluxes it has to be assumed that a laminar sublayer cannot exist in the immediate vicinity of a red hot heating surface. A mechanistic model is proposed which is based on the assumption that due to bubble growth and collapse the maximum turbulence intensity is located at the wall/liquid interface and that eddy diffusivity decreases with increasing wall distance.     

Fundamental Issues Related to Flow Boiling and Two-Phase Flow Patterns in Microchannels – Experimental Challenges and Opportunities

ABSTRACT

Flow boiling heat transfer in microchannels is used today in many diverse applications. The previous studies addressing the effect of channel size, heat flux, vapor quality, and mass flux on heat transfer during flow boiling are reviewed in the present paper. The relationship between flow characteristics and flow boiling heat transfer was studied experimentally for refrigerant R-C318 at moderate reduced pressures where the contribution of nucleate boiling is decisive. Flow boiling mechanisms were identified using an annular microchannel with transparent outer wall for successive visualization of boiling. The considerable suppression of nucleate boiling heat transfer was observed at transition to annular flow and explained by formation of a liquid flow with thin film and dry spots. A general equation for prediction of two-phase flow boiling heat transfer inside the circular, annular, and rectangular microchannels is proposed and verified using the experimental data. This equation accounts for the nucleate boiling suppression, forced convection, and thin film evaporative heat transfer in the form that allows to distinguish more clearly the contribution of each mechanism of heat transfer under the conditions, when it is predominant. A new approach for prediction of transition to the annular flow is proposed and verified, using the experimental data.     

Enhanced heat transfer performance of alumina sponge-like nano-porous structures through surface wettability control in nucleate pool boiling

For several decades, a porous surface has been recognized as an efficient medium to increase boiling performance in a nucleate boiling regime. Most feasible porous surfaces have been studied in millimeter and micron-sized domains. It has been believed that a higher wall superheat is required to commence incipient nucleate boiling under a submicron regime. In this study, we demonstrate that a significantly enhanced pool boiling heat transfer is observed in a submicron regime through three dimensionally interconnected hybrid pores: the Alumina sponge-like nano-porous structure (ASNPS). The structural uniqueness of the ASNPS leads to an enlarged surface area, increases the potential number of the active nucleation site density, and improves the vapor–liquid menisci through the reentrant pore. Simultaneously, by changing the surface wettability with a hydrophobic self-assembled monolayer (SAM) coating, the number of active nucleation site density is improved. Eventually, the combination of the ASNPS and hydrophobic SAM coating can achieve substantial heat transfer coefficient (HTC) enhancement in the nucleate boiling. Also, the thickness of the ASNPS is a critical issue to adequately augment the HTC in pool boiling. The thickness of the ASNPS is optimized by examining the boiling performance of the ASNPS fabricated in different amounts of anodizing times. A classical mechanistic model from literature was modified and compared with the experimentally obtained data. The modified mechanistic model – with the combination of forced-convection and thin liquid film evaporation – showed reasonable predictions.     

Characteristics of boiling curve in transition region between nucleate boiling and film boiling

An experimental study has been carried out for estimating surface temperature and heat flux during both a transient heating process from nucleate boiling to film boiling and a cooling process in the reverse direction. Experiments were at atmospheric pressure, and calculations used a newly developed inverse solution. Three different materials, gold, copper, and brass, were employed to make clear the effect of thermal properties on the boiling curves in the transient region including the maximum and minimum heat fluxes. It was determined that the histories of surface temperature and heat flux for the transition boiling region during either heating or cooling process can be tracked well. The experiment shows that hysteresis exists in the heating and cooling processes for the transition region while no hysteresis exists in the nucleate boiling region, except that the maximum heat fluxes reached during the heating and cooling processes are much different. It was found that the characteristics for the heating process are minimally influenced by thermal properties, while characteristics of the cooling process are greatly affected. © 2005 Wiley Periodicals, Inc. Heat Trans Asian Res, 35(1): 20–34, 2006; Published online in Wiley InterScience ( www.interscience.wiley.com ). DOI 10.1002/htj.20097     

Boiling time effect on CHF enhancement in pool boiling of nanofluids

Using TiO₂–water nanofluids as the test liquid, pool boiling experiments were carried out to investigate the dependence of the nucleate boiling heat transfer, surface wettability and critical heat flux (CHF) on the boiling time in nanofluids. In the experiments performed at sufficiently high nanoparticle concentrations, the boiling heat transfer first degraded, then improved, and finally reached an equilibrium state. It was hence supposed that the present nanofluids had competing effects to deteriorate and enhance the nucleate boiling heat transfer. As for the surface wettability and CHF, the static contact angle asymptotically decreased whilst the CHF asymptotically increased with an increase in the boiling time. The maximum CHF enhancement measured in the present experiments was 91%, and strong correlation was found between the contact angle and the CHF. Although the boiling time needed to achieve the maximum CHF enhancement was less than a minute at high particle concentrations, a longer time of the order of 1 h was necessary at the lowest particle concentration tested in this work. This experimental result indicated that sufficient attention should be paid to the boiling time effect particularly in industrial applications of nanofluids to emergency cooling.     

Simultaneous visualization of dry spots and bubbles for pool boiling of R-113 on a horizontal heater

A new experimental attempt was made to simultaneously observe the dynamic behaviors of bubbles and dry spots in the vicinity of boiling surface. Also, the two-dimensional bubble structures were obtained separately. From the visualization results, the formation of bubbles and dry spots occurs simultaneously. At critical heat flux (CHF), the surface rewetting is repeated by the local nucleate boiling around the large vapor film. At just after CHF, nucleate boiling at the locally wetted region is extinguished, resulting in the dryout of the whole heater surface. Therefore, we conclude that CHF is initiated from the locally limited nucleate boiling activity rather than any hydrodynamic instability.     

Nucleate boiling on the superhydrophilic surface with a small water impingement jet

In this study, the coating process on the copper surface with titanium dioxide (TiO₂) has been introduced. The coated surface exhibits extremely high affinity for water and the solid–liquid contact angle decreases nearly to zero by exposing the surface to ultra-violet light. This superhydrophilic characteristic was applied to nucleate boiling heat transfer of water jet impingement on a flat heated plate. By making use of this special heat transfer surface, the nucleate boiling heat transfer and the critical heat flux (CHF) of a bar water jet impingement on a large flat superhydrophilic surface was experimentally investigated. The experimental data were measured in a steady state. The purified water was employed as the working liquid. Three main influencing factors, i.e., subcooling, impact velocity and the surface coating condition, were changed and their effects on the nucleate boiling heat transfer and the CHF were investigated. The empirical correlations were obtained for predicting the CHF of steady boiling for a small round water jet impingement on a large flat superhydrophilic surface. The experimental results show that the CHF on the superhydrophilic surface is about 30% higher than that on conventional copper surface by decreasing the solid–liquid contact angle.     

Nucleate and film boiling on a microheater under pulse heating in a microchannel

Using MEMS technology, a Pt microheater (60 × 100 µm²) fabricated on a glass wafer is placed in a silicon-based microchannel of trapezoidal cross section. With the aid of a high-speed CCD and based on Pt's linear temperature-resistance characteristic, flow boiling phenomena and temperature response on the surface of the microheater in the microchannel under pulse heating are observed and recorded. At a given mass flux, nucleate boiling and film boiling begin to appear on the microheater with increasing heat flux. A flow boiling map, showing the effects of heat and mass flux on nucleate and film boiling regimes on the microheater at a pulse heating width of 2 ms, is presented. It is found that nucleate boiling is changed to film boiling as the heat flux supplied to the microheater is increased. Furthermore, increasing mass flux increases the heat flux required for the incipience of nucleate boiling and film boiling on the microheater in the microchannel.     

Non-linear dynamical analyses of transient surface temperature fluctuations during subcooled pool boiling on a horizontal disk

The class of dynamics in pool boiling on a large-size heater is assessed under subcooled pool boiling conditions. Transient surface temperature measurements are obtained using surface micro-machined K-type thin film thermocouples (TFT) in 10 °C subcooled pool boiling experiments on a 62.23 mm diameter silicon wafer using PF-5060 as the test liquid. Surface temperature data is obtained at each steady state condition to generate the boiling curve. The fraction of false-nearest neighbors, recurrence plots and space–time separation plots are obtained using the TISEAN package. The correlation dimension is then estimated from the re-constructed phase space data using a naïve algorithm. The correlation dimension varies from ～11.2 to 11.5 near onset of nucleate boiling (ONB), to ～7–10 in fully developed nucleate boiling (FDNB) ～7–9 near critical heat flux (CHF) condition, and from ～6.6 to 7.7 in film boiling. False-nearest neighbor estimates and recurrence plots show that nucleate boiling may be dominated by statistical processes near ONB and in partial nucleate boiling (PNB). In contrast, FDNB, CHF and film boiling seem chaotic and governed by deterministic processes.     

A nucleate boiling limitation model for the prediction of pool boiling CHF

A nucleate boiling limitation model which is applicable to the heat transfer prediction in the nucleate boiling region and the CHF was proposed for a pool boiling. The present model was developed based on the direct observations of the physical boiling phenomena. The predicted boiling curves for the nucleate boiling region agree well with both the vertical and the horizontal surface data for all the contact angles. The predicted CHF for the vertical surface also agrees well with the experimental data, but the present model underpredicts the CHF by about 30% for the horizontal surface data.