Surface wettability control by nanocoating: The effects on pool boiling heat transfer and nucleation mechanism

Experiments were performed to highlight the influence of surface wettability on nucleate boiling heat transfer. Nanocoating techniques were used to vary the water contact angle from 20° to 110° by modifying nanoscale surface topography and chemistry. The bubble growth was recorded by a high speed video camera to enable a better understanding of the surface wettability effects on nucleation mechanism. For hydrophilic (wetted) surfaces, it was found that a greater surface wettability increases the vapour bubble departure radius and reduces the bubble emission frequency. Moreover, lower superheat is required for the initial growth of bubbles on hydrophobic (unwetted) surfaces. However, the bubble in contact with the hydrophobic surface cannot detach from the wall and have a curvature radius increasing with time. At higher heat flux, the bubble spreads over the surface and coalesces with bubbles formed at other sites, causing a large area of the surface to become vapour blanketed. The best heat transfer coefficient is obtained with the surface which had a water contact angle close to either 0° or 90°. A new approach of nucleation mechanism is established to clarify the nexus between the surface wettability and the nucleate boiling heat transfer.     

Critical Heat Flux of Boiling Heat Transfer in a Moderate Narrow Space

INTanDUCTI0NBoilingheattransferandcriticalheatflux(CHF)inaconfinednarrowspacehavebeenstudiedexperi-melltallybyanumberofinvestigatorsinthepastfewdecades.However,thereisnoanypopularlyacceptedmodelintheheattransferinnarrowspaceboiling,althoughsomepopularknowledgeabouttheboilingheattransferinthenarrowspacehavebeenacceptedbymanyresearchers.Theknowledgecanbecon-cludedasthatthenucleateboilingheattransferisenhancedatlowheatfluxregionanddeterioratedathighheatfiuxregi0nespeciallyatCHF.Theenhanceme…     

Duhamel integral form for the interface heat flux between bubble and liquid

The solution of heat equation inside oscillating gas bubble with moving boundary was obtained by Fourier’s method. The integral formula for interface heat flux, containing theta-function in the integrand was derived. The kernel of the integral is represented by a series of exponential functions, and a simple analytic approximation obtained earlier is used for it with high accuracy. The asymptotic expression for the interface heat flux in the Duhamel integral form with rooted kernel was derived.The vapor bubbles were also considered. In this case the major problem is external heat problem in liquid. It is shown that the asymptotic expression for the heat flux at the interface in the case of gas bubbles has the similar structure as the heat flux from the vapor bubble surface to the liquid. In both cases it is Duhamel integral with rooted kernel.     

Subcooled flow boiling heat transfer of R-134a and the associated bubble characteristics in a vertical plate heat exchanger

Subcooled flow boiling heat transfer characteristics of refrigerant R-134a in a vertical plate heat exchanger (PHE) are investigated experimentally in this study. Besides, the associated bubble characteristics are also inspected by visualizing the boiling flow in the vertical PHE. In the experiment two vertical counterflow channels are formed in the exchanger by three plates of commercial geometry with a corrugated sinusoidal shape of a chevron angle of 60°. Upflow boiling of subcooled refrigerant R-134a in one channel receives heat from the downflow of hot water in the other channel. The effects of the boiling heat flux, refrigerant mass flux, system pressure and inlet subcooling of R-134a on the subcooled boiling heat transfer are explored in detail. The results are presented in terms of the boiling curves and heat transfer coefficients. The measured data showed that the slopes of the boiling curves change significantly during the onset of nucleate boiling (ONB) especially at low mass flux and high saturation temperature. Besides, the boiling hysteresis is significant at a low refrigerant mass flux. The subcooled boiling heat transfer coefficient is affected noticeably by the mass flux of the refrigerant. However, increases in the inlet subcooling and saturation temperature only show slight improvement on the boiling heat transfer coefficient.The photos from the flow visualization reveal that at higher imposed heat flux the plate surface is covered with more bubbles and the bubble generation frequency is substantially higher, and the bubbles tend to coalesce to form big bubbles. But these big bubbles are prone to breaking up into small bubbles as they move over the corrugated plate, producing strong agitating flow motion and hence enhancing the boiling heat transfer. We also note that the bubbles nucleated from the plate are suppressed to a larger degree for higher inlet subcooling and mass flux. Finally, empirical correlations are proposed to correlate the present data for the heat transfer coefficient and the bubble departure diameter in terms of boiling, Froude, Reynolds and Jakob numbers.     

Saturated flow boiling heat transfer of R-407C and associated bubble characteristics in a narrow annular duct

Experiments are conducted here to investigate how the channel size affects the R-407C saturated flow boiling heat transfer and associated bubble characteristics in a horizontal narrow annular duct. The gap of the duct is fixed at 1.0 and 2.0 mm in this study. The measured data indicate that the saturated flow boiling heat transfer coefficient increases with a decrease in the duct gap. Besides, raising the imposed heat flux can cause a significant increase in the boiling heat transfer coefficients. However, the effects of the refrigerant mass flux and saturated temperature on the boiling heat transfer coefficient are milder. The results from the flow visualization show that the mean diameter of the bubbles departing from the heating surface decreases noticeably at increasing R-407C mass flux. Moreover, the bubble departure frequency increases at reducing duct size and at a high imposed heat flux many bubbles generated from the cavities in the heating surface tend to merge together to form big bubbles. Meanwhile comparison of the present heat transfer data for R-407C with R-134a in the same duct and with some existing correlations is conducted. Furthermore, correlation for the present R-407C saturated flow boiling heat transfer data is proposed. Additionally, the present data for some quantitative bubble characteristics such as the mean bubble departure diameter and frequency and the active nucleation site density are also correlated.     

Prediction and measurement of incipient boiling heat flux in micro-channel heat sinks

Experiments were performed to measure the incipient boiling heat flux in a heat sink containing 21 rectangular (231 μm wide and 713 μm deep) micro-channels. Tests were performed using deionized water with inlet liquid velocities of 0.13-1.44 m/s, inlet temperatures of 30, 60 and 90 °C, and an outlet pressure of 1.2 bar. Using a microscope, boiling incipience was identified when the first bubbles were detected growing at, and departing from the micro-channel wall near the outlet. A comprehensive model was developed to predict the incipient boiling heat flux, accounting for the complexities of bubble formation along the flat and corner regions of a rectangular flow channel, as well as the likelihood of bubbles growing sufficiently large to engulf the entire flow area of a micro-channel. The model is based on a bubble departure criterion, which combines both mechanical considerations (force balance on a bubble) and thermal considerations (superheating entire bubble interface). The model shows good agreement with the experimental results.     

Saturated flow boiling heat transfer of R-410A and associated bubble characteristics in a narrow annular duct

Experiments are conducted here to investigate how the channel size affects the R-410A saturated flow boiling heat transfer and associated bubble characteristics in a horizontal narrow annular duct. The gap of the duct is fixed at 1.0 and 2.0 mm in this study. The measured data indicate that the saturated flow boiling heat transfer coefficient increases with increasing refrigerant mass flux and saturated temperature and with a decrease in the gap size. Besides, raising the imposed heat flux can cause a significant increase in the boiling heat transfer coefficient. The results from the flow visualization show that the mean diameter of the bubbles departing from the heating surface decreases slightly with increasing refrigerant mass flux and saturated temperature. Moreover, the bubble departure frequency increases at reducing duct size and increasing mass flux. And at a high imposed heat flux many bubbles generated from the cavities in the heating surface tend to merge together to form big bubbles. Meanwhile, comparisons of the present heat transfer data for R-410A with R-407C and R-134a in the same duct and with some existing correlations are conducted. Furthermore, an empirical correlation for the present R-410A saturated flow boiling heat transfer data is proposed.     

Subcooled flow boiling heat transfer and associated bubble characteristics of R-134a in a narrow annular duct

Experiments are conducted here to investigate how the channel size affects the subcooled flow boiling heat transfer and associated bubble characteristics of refrigerant R-134a in a horizontal narrow annular duct. The gap of the duct is fixed at 1.0 and 2.0 mm in this study. From the measured boiling curves, the temperature undershoot at ONB is found to be relatively significant for the subcooled flow boiling of R-134a in the duct. The R-134a subcooled flow boiling heat transfer coefficient increases with a reduction in the gap size, but decreases with an increase in the inlet liquid subcooling. Besides, raising the imposed heat flux can cause a substantial increase in the subcooled boiling heat transfer coefficient. However, the effects of the refrigerant mass flux and saturated temperature on the boiling heat transfer coefficient are small in the narrow duct. Visualization of the subcooled flow boiling processes reveals that the bubbles are suppressed to become smaller and less dense by raising the refrigerant mass flux and inlet subcooling. Moreover, raising the imposed heat flux significantly increases the bubble population, coalescence and departure frequency. The increase in the bubble departure frequency by reducing the duct size is due to the rising wall shear stress of the liquid flow, and at a high imposed heat flux many bubbles generated from the cavities on the heating surface tend to merge together to form big bubbles. Correlation for the present subcooled flow boiling heat transfer data of R-134a in the narrow annular duct is proposed. Additionally, the present data for some quantitative bubble characteristics such as the mean bubble departure diameter and frequency and the active nucleation site density are also correlated.     

A Photographic study of subcooled flow boiling burnout at high heat flux and velocity

The present paper reports the results of a visualization study of the burnout in subcooled flow boiling of water, with square cross section annular geometry (formed by a central heater rod contained in a duct characterized by a square cross section). The coolant velocity is in the range 3–10 m/s. High speed movies of flow pattern in subcooled flow boiling of water from the onset of nucleate boiling up to physical burnout of the heater are recorded. From video images (single frames taken with a stroboscope light and an exposure time of 1 μs), the following general behaviour of vapour bubbles was observed: when the rate of bubble generation is increasing, with bubbles growing in the superheated layer close to the heating wall, their coalescence produces a type of elongated bubble called vapour blanket. One of the main features of the vapour blanket is that it is rooted to the nucleation site on the heated surface. Bubble dimensions are given as a function of thermal-hydraulic tested conditions for the whole range of velocity until the burnout region. A qualitative analysis of the behaviour of four stainless steel heater wires with different macroscopic surface finishes is also presented, showing the importance of this parameter on the dynamics of the bubbles and on the critical heat flux.     

Saturated flow boiling heat transfer and associated bubble characteristics of R-134a in a narrow annular duct

Experiments are conducted here to investigate how the channel size affects the saturated flow boiling heat transfer and associated bubble characteristics of refrigerant R-134a in a horizontal narrow annular duct. The gap of the duct is fixed at 1.0 and 2.0 mm in this study. The measured heat transfer data indicate that the saturated flow boiling heat transfer coefficient increases with a decrease in the gap of the duct. Besides, raising the imposed heat flux can cause a significant increase in the boiling heat transfer coefficients. However, the effects of the refrigerant mass flux and saturated temperature on the boiling heat transfer coefficient are milder. The results from the flow visualization show that the mean diameter of the bubbles departing from the heating surface decreases slightly at increasing R-134a mass flux. Moreover, the bubble departure frequency increases at reducing duct size mainly due to the rising shear stress of the liquid flow, and at a high imposed heat flux many bubbles generated from the cavities in the heating surface tend to merge together to form big bubbles. Correlation for the present saturated flow boiling heat transfer data of R-134a in the narrow annular duct is proposed. Additionally, data for some quantitative bubble characteristics such as the mean bubble departure diameter and frequency and the active nucleation site density are also correlated.     

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.     

Numerical investigation of fluid flow and heat transfer under high heat flux using rectangular micro-channels

A 3D-conjugate numerical investigation was conducted to predict heat transfer characteristics in a rectangular cross-sectional micro-channel employing simultaneously developing single-phase flows. The numerical code was validated by comparison with previous experimental and numerical results for the same micro-channel dimensions and classical correlations based on conventional sized channels. High heat fluxes up to 130 W/cm² were applied to investigate micro-channel thermal characteristics. The entire computational domain was discretized using a 120 × 160 × 100 grid for the micro-channel with an aspect ratio of (α = 4.56) and examined for Reynolds numbers in the laminar range (Re 500–2000) using FLUENT. De-ionized water served as the cooling fluid while the micro-channel substrate used was made of copper. Validation results were found to be in good agreement with previous experimental and numerical data [1] with an average deviation of less than 4.2%. As the applied heat flux increased, an increase in heat transfer coefficient values was observed. Also, the Reynolds number required for transition from single-phase fluid to two-phase was found to increase. A correlation is proposed for the results of average Nusselt numbers for the heat transfer characteristics in micro-channels with simultaneously developing, single-phase flows.     

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.     

Bounds on natural convective heat transfer in a porous layer with fixed heat flux

Using the background field variational method, bounds on natural convective heat transfer in a porous layer heated from below with fixed heat flux are derived from the primitive equations. The enhancement of heat transfer beyond the minimal conduction value (the Nusselt number Nu) is bounded in terms of the non-dimensional forcing scale set by the ‘effective’ Rayleigh number (Rˆ) according to Nu ≤ 0.354Rˆ^1/2 and in terms of the conventional Rayleigh number (Ra) defined by the temperature drop across the layer according to Nu ≤ 0.125Ra. It is presented that fixing the heat flux at the boundaries does not change the linear dependence between Nusselt number and Rayleigh number at high Rayleigh number region.     

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.     

New proposed two-phase multiplier and evaporation heat transfer coefficient correlations for R134a flowing at low mass flux in a multiport minichannel

New correlations of the two-phase multiplier and heat transfer coefficient of R134a during evaporation in a multiport minichannel at low mass flux are proposed. The experimental results were obtained from a test using a counter-flow tube-in-tube heat exchanger with refrigerant flowing in the inner tube and hot water in the gap between the outer and inner tubes. Test section is composed of the extruded multiport aluminium inner tube with an internal hydraulic diameter of 1.2 mm and an acrylic outer tube with an internal hydraulic diameter of 25.4 mm. The experiments were performed at heat fluxes between 10 and 35 kW/m², and a refrigerant mass flux between 45 and 155 kg/(m² s). Some physical parameters that influenced the frictional pressure drop and heat transfer coefficient are examined and discussed in detail. The pressure drop and heat transfer coefficient results are also compared with existing correlations. Finally, new correlations for predicting the frictional pressure drop and heat transfer coefficient at low mass fluxes are proposed.     

On the dynamics and heat transfer of bubble train in micro-channel flow boiling

The dynamics and heat transfer characteristics of flow boiling bubble train moving in a micro channel is studied numerically. The coupled level set and volume of fluid (CLSVOF) is utilized to track interface and a non-equilibrium phase change model is applied to calculate the interface temperature as well as heat flux jump. The working fluid is R134a and the wall material is aluminum. The fluid enters the channel with a constant mass flux (335 kg/m² 1 s), and the boundary wall is heated with constant heat flux (14 kW/m²). The growth of bubbles and the transition of flow regime are compared to an experimental visualization. Moreover, the bubble evaporation rate and wall heat transfer coefficient have been examined, respectively. Local heat transfer is significantly enhanced by evaporation occurring vicinity of interface of the bubbles. The local wall temperature is found to be dependent on the thickness of the liquid film between the bubble train and the wall.     

Bubble growth and horizontal coalescence in saturated pool boiling on a titanium foil,investigated by high-speed IR thermography

Growth of an isolated bubble and horizontal coalescence events between bubbles of dissimilar size were examined during pool nucleate boiling of water on a horizontal, electrically-heated titanium foil 25 μm thick. Wall temperature measurements on the back of the foil by high-speed IR camera, synchronized with high-speed video camera recordings of the bubble motion, improved the temporal and spatial resolution of previous observations by high-speed liquid crystal thermography to 1 ms and 40 μm, respectively, leading to better detailed maps of the transient distributions of wall heat flux. The observations revealed complex behaviour that disagreed with some other observations and current modelling assumptions for the mechanisms of heat transfer over the wall contact areas of bubbles and interactions between bubbles. Heat transfer occurred from the entire contact area and was not confined to a narrow peripheral triple-contact zone. There was evidence of an asymmetrical interaction between bubbles before coalescence. It was hypothesised that a fast-growing bubble pushed superheated liquid under a slow-growing bubble. Contact of this liquid with regions of the wall that had been pre-cooled during bubble growth caused local reductions in the wall heat flux. During coalescence, movement of liquid under both bubbles caused further changes in the wall heat flux that also depended on pre-cooling. Contraction of the contact area caused a peripheral reduction in the heat flux and there was no evidence of a large increase in heat flux during detachment. Boiling on very thin foils imposes special conditions. Sensitivity to the thermal history of the wall must be taken into account when applying the observations and hypotheses to other conditions.     

On the rise paths of single vapor bubbles after the departure from nucleation sites in subcooled upflow boiling

A photographic study was carried out for the subcooled flow boiling of water to elucidate the rise characteristics of single vapor bubbles after the departure from nucleation sites. The test section was a transparent glass tube of 20 mm in inside diameter and the flow direction was vertical upward; liquid subcooling was parametrically changed within 0–16 K keeping system pressure and liquid velocity at 120 kPa and 1 m/s, respectively. The bubble rise paths were analyzed from the video images that were obtained at the heat flux slightly higher than the minimum heat flux for the onset of nucleate boiling. In the present experiments, all the bubbles departed from their nucleation sites immediately after the inception. In low subcooling experiments, bubbles slid upward and consequently were not detached from the vertical heated wall; the bubble size was increased monotonously with time in this case. In moderate and high subcooling experiments, bubbles were detached from the wall after sliding for several millimeters and migrated towards the subcooled bulk liquid. The bubbles then reversed the direction of lateral migration and were reattached to the wall at moderate subcooling while they collapsed due to the condensation at high subcooling. It was hence considered that the mechanisms of the heat transfer from heated wall and the axial growth of vapor volume were influenced by the difference in bubble rise path. It was observed after the inception that bubbles were varied from flattened to more rounded shape. This observation suggested that the bubble detachment is mainly caused by the change in bubble shape due to the surface tension force.     

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.