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.     

Subcooled flow boiling heat transfer and associated bubble characteristics of FC-72 on a heated micro-pin-finned silicon chip

Experiments are conducted here to investigate subcooled flow boiling heat transfer and associated bubble characteristics of FC-72 on a heated micro-pin-finned silicon chip flush-mounted on the bottom of a horizontal rectangular channel. In the experiments the mass flux is varied from 287 to 431 kg/m² s, coolant inlet subcooling from 2.3 to 4.3 °C, and imposed heat flux from 1 to 10 W/cm². Besides, the silicon chips contain three different geometries of micro-structures, namely, the smooth, pin-finned 200 and pin-finned 100 surfaces. The pin-finned 200 and 100 surfaces, respectively, contain micro-pin-fins of size 200 μm × 200 μm × 70 μm (width × length × height) and 100 μm × 100 μm × 70 μm. The measured data show that the subcooled flow boiling heat transfer coefficient is reduced at increasing inlet liquid subcooling but is little affected by the coolant mass flux. Besides, adding the micro-pin-fin structures to the chip surface can effectively raise the single-phase convection and flow boiling heat transfer coefficients. Moreover, the mean bubble departure diameter and active nucleation site density are reduced for rises in the FC-72 mass flux and inlet liquid subcooling. Increasing coolant mass flux or reducing inlet liquid subcooling results in a higher mean bubble departure frequency. Furthermore, larger bubble departure diameter, higher bubble departure frequency, and higher active nucleation site density are observed as the imposed heat flux is increased. Finally, empirical correlations for the present data for the heat transfer and bubble characteristics in the FC-72 subcooled flow boiling are proposed.     

Saturated flow boiling heat transfer and associated bubble characteristics of FC-72 on a heated micro-pin-finned silicon chip

An experiment is carried out here to investigate flow boiling heat transfer and associated bubble characteristics of FC-72 on a heated micro-pin-finned silicon chip flush-mounted in the bottom of a horizontal rectangular channel. Besides, three different micro-structures of the chip surface are examined, namely, the smooth, pin-finned 200 and pin-finned 100 surfaces. The pin-finned 200 and 100 surfaces, respectively, contain micro-pin-fins of size 200 μm × 200 μm × 70 μm (width × length × height) and 100 μm × 100 μm × 70 μm. The pitch of the fins is equal to the fin width for both surfaces. The effects of the FC-72 mass flux, imposed heat flux, and surface micro-structures of the silicon chip on the FC-72 saturated flow boiling characteristics are examined in detail. The experimental data show that an increase in the FC-72 mass flux causes a delay in the boiling incipience. However, the flow boiling heat transfer coefficient is not affected by the coolant mass flux. But adding the micro-pin-fin structures to the chip surfaces can effectively enhance the single-phase convection and flow boiling heat transfer. Moreover, the mean bubble departure diameter and active nucleation site density are reduced for a rise in the FC-72 mass flux. A higher coolant mass flux results in a higher mean bubble departure frequency. Furthermore, larger bubble departure diameter, higher bubble departure frequency, and higher active nucleation site density are observed at a higher imposed heat flux. We also note that adding the micro-pin-fins to the chips decrease the bubble departure diameter and increase the bubble departure frequency. However, the departing bubbles are larger for the pin-finned 100 surface than the pin-finned 200 surface but the bubble departure frequency exhibits an opposite trend. Finally, empirical equations to correlate the present data for the FC-72 single-phase liquid convection and saturated flow boiling heat transfer coefficients and for the bubble characteristics are provided.     

Comparison of numerical and experimental performance criteria of an ammonia–water bubble absorber using plate heat exchangers

A mathematical model for ammonia–water bubble absorbers was developed and compared with experimental data using a plate heat exchanger. The analysis was performed carrying out a sensitive study of selected operation parameters on the absorber thermal load and mass absorption flux. Regarding the experimental data, the values obtained for the solution heat transfer were in the range 0.51–1.21 kW m^?2 K^?1 and those of the mass absorption flux in the range 2.5–5.0 × 10^?3 kg m^?2 s^?1. The comparison between experimental and simulation results was acceptable being the maximum difference of 11.1% and 28.4% for the absorber thermal load and the mass absorption flux, respectively.     

Heat transfer and pressure drop during HFC refrigerant saturated vapour condensation inside a brazed plate heat exchanger

This paper presents the heat transfer coefficients and the pressure drop measured during HFC refrigerants 236fa, 134a and 410A saturated vapour condensation inside a brazed plate heat exchanger: the effects of saturation temperature (pressure), refrigerant mass flux and fluid properties are investigated. The heat transfer coefficients show weak sensitivity to saturation temperature (pressure) and great sensitivity to refrigerant mass flux and fluid properties. A transition point between gravity controlled and forced convection condensation has been found for a refrigerant mass flux around 20 kg/m²s that corresponds to an equivalent Reynolds number around 1600–1700. At low refrigerant mass flux (G_r < 20 kg/m²s) the heat transfer coefficients are not dependent on mass flux and are well predicted by the Nusselt [20] analysis for vertical surface: the condensation process is gravity controlled. For higher refrigerant mass flux (G_r > 20 kg/m²s) the heat transfer coefficients depend on mass flux and are well predicted by Akers et al. [21] equation: forced convection condensation occurs. In the forced convection condensation region the heat transfer coefficients show a 25–30% increase for a doubling of the refrigerant mass flux.The frictional pressure drop shows a linear dependence on the kinetic energy per unit volume of the refrigerant flow and therefore a quadratic dependence on mass flux.HFC-410A shows heat transfer coefficients similar to HFC-134a and 10% higher than HFC-236fa together with frictional pressure drops 40-50% lower than HFC-134a and 50–60% lower than HFC-236fa.     

Local measurement of flow boiling in structured surface microchannels

Experiments were conducted to investigate flow boiling in 200 μm × 253 μm parallel microchannels with structured reentrant cavities. Flow morphologies, boiling inceptions, heat transfer coefficients, and critical heat fluxes were obtained and studied for mass velocities ranging from G = 83 kg/m² s to G = 303 kg/m² s and heat fluxes up to 643 W/cm². Comparisons of the performance of the enhanced and plain-wall microchannels were performed. The microchannels with reentrant cavities were shown to promote nucleation of bubbles and to support significantly better reproducibility and uniformity of bubble generation. The structured surface was also shown to significantly reduce the boiling inception and to enhance the critical heat flux.     

Experimental study of R-134a evaporation heat transfer in a narrow annular duct

An experiment is carried out here to investigate the evaporation heat transfer and associated evaporating flow pattern for refrigerant R-134a flowing in a horizontal narrow annular duct. The gap of the duct is fixed at 1.0 and 2.0 mm. In the experiment, the effects of the duct gap, refrigerant vapor quality, mass flux and saturation temperature and imposed heat flux on the measured evaporation heat transfer coefficient h_r are examined in detail. For the duct gap of 2.0 mm, the refrigerant mass flux G is varied from 300 to 500 kg/m² s, imposed heat flux q from 5 to 15 kW/m², vapor quality x_m from 0.05 to 0.95, and refrigerant saturation temperature T_sat from 5 to 15 °C. While for the gap of 1.0 mm, G is varied from 500 to 700 kg/m² s with the other parameters varied in the same ranges as that for δ = 2.0 mm. The experimental data clearly show that the evaporation heat transfer coefficient increases almost linearly with the vapor quality of the refrigerant and the increase is more significant at a higher G. Besides, the evaporation heat transfer coefficient also rises substantially at increasing q. Moreover, a significant increase in the evaporation heat transfer coefficient results for a rise in T_sat, but the effects are less pronounced in the narrower duct at a low imposed heat flux and a high refrigerant mass flux. Furthermore, the evaporation heat transfer coefficient increases substantially with the refrigerant mass flux except at low vapor quality. We also note that reducing the duct gap causes a significant increase in h_r. In addition to the heat transfer data, photos of R-134a evaporating flow taken from the duct side show the change of the dominant two-phase flow pattern in the duct with the experimental parameters. Finally, an empirical correlation for the present measured heat transfer coefficient for the R-134a evaporation in the narrow annular ducts is proposed.     

Effects of surfactant additive on flow boiling over a microheater under pulse heating

An experimental investigation has been carried out to study effects of surfactant additive on microscale boiling under pulse heating over a Pt microheater (140 × 100 μm²) fabricated in a trapezoidal microchannel (600 μm in width and 150 μm in depth). Experiments are carried out for six different surfactant concentrations of Triton X-100 ranging from 47 ppm to 2103 ppm, for mass flux in the range from 45 kg/m² s to 225 kg/m² s, pulse width in the range from 50 μs to 2 ms, and heat flux in the range from 3 MW/m² to 65 MW/m². As in existing work on pool boiling under steady heating, it is found that nucleate boiling becomes more vigorous and heat transfer is enhanced greatly with the addition of surfactant with maximum boiling heat transfer occurs at the critical micelle concentration (cmc). Furthermore, these maximum values of boiling heat transfer coefficient increase with decreasing pulse width. When concentration is below cmc, the heat flux needed for nucleation increases with increasing concentration and the nucleation temperature is reduced. When concentration is higher than cmc, the boiling heat transfer coefficient decreases and nucleation temperature is higher than that of pure water.     

Experimental study of evaporation heat transfer characteristics of refrigerants R-134a and R-407C in horizontal small tubes

An experiment is carried out here to investigate the characteristics of the evaporation heat transfer for refrigerants R-134a and R-407C flowing in horizontal small tubes having the same inside diameter of 0.83 or 2.0 mm. In the experiment for the 2.0-mm tubes, the refrigerant mass flux G is varied from 200 to 400 kg/m² s, imposed heat flux q from 5 to 15 kW/m², inlet vapor quality x_in from 0.2 to 0.8 and refrigerant saturation temperature T_sat from 5 to 15 °C. While for the 0.83-mm tubes, G is varied from 800 to 1500 kg/m² s with the other parameters varied in the same ranges as those for D_i = 2.0 mm. In the study the effects of the refrigerant vapor quality, mass flux, saturation temperature and imposed heat flux on the measured evaporation heat transfer coefficient h_r are examined in detail. The experimental data clearly show that both the R-134a and R-407C evaporation heat transfer coefficients increase almost linearly and significantly with the vapor quality of the refrigerant, except at low mass flux and high heat flux. Besides, the evaporation heat transfer coefficients also increase substantially with the rises in the imposed heat flux, refrigerant mass flux and saturation temperature. At low R-134a mass flux and high imposed heat flux the evaporation heat transfer coefficient in the smaller tubes (D_i = 0.83 mm) may decline at increasing vapor quality when the quality is high, due to the partial dryout of the refrigerant flow in the smaller tubes at these conditions. We also note that under the same x_in, T_sat, G, q and D_i, refrigerant R-407C has a higher h_r when compared with that for R-134a. Finally, an empirical correlation for the R-134a and R-407C evaporation heat transfer coefficients in the small tubes is proposed.     

Heat transfer characteristics during subcooled flow boiling of a kerosene kind hydrocarbon fuel in a 1 mm diameter channel

The subcooled flow boiling heat transfer characteristics of a kerosene kind hydrocarbon fuel were investigated in an electrically heated horizontal tube with an inner diameter of 1.0 mm, in the range of heat flux: 20–1500 kW/m², fluid temperature: 25–400 °C, mass flux: 1260–2160 kg/m² s, and pressure: 0.25–2.5 MPa. It was proposed that nucleate boiling heat transfer mechanism is dominant, as the heat transfer performance is dependent on heat flux imposed on the channel, rather than the fuel flow rate. It was found that the wall temperatures along the test section kept constant during the fully developed subcooled boiling (FDSB) of the non-azeotropic hydrocarbon fuel. After the onset of nucleate boiling, the temperature differences between inner wall and bulk fluid begin to decrease with the increase of heat flux. Experimental results show that the complicated boiling heat transfer behavior of hydrocarbon fuel is profoundly affected by the pressure and heat flux, especially by fuel subcooling. A correlation of heat transfer coefficients varying with heat fluxes and fuel subcooling was curve fitted. Excellent agreement is obtained between the predicted values and the experimental data.     

On the eruptive boiling in silicon-based microchannels

This study investigates experimentally eruptive boiling in a silicon-based rectangular microchannel with a hydraulic diameter of 33.7 μm, a width of 99.8 μm and a depth-to-width ratio of 0.203. The microchannel is made of SOI wafer and prepared using bulk micro-machining and anodic bonding. The surface roughness for both the bottom and the side walls was measured using an atomic force microscope. The evolution of the eruptive boiling of water in the smooth microchannel was clearly observed using an ultra high-speed video camera (up to 50,000 frames/s) at mass fluxes of 417 and 625 kg/m² s and a heat flux from 14.9 to 372 kW/m². It is confirmed that eruptive boiling is a form of rapid bubble nucleation after which the bubble merges with a slug bubble downstream in a short distance or evolve to a slug bubble. The bubble frequency in all of the cases studied is provided. Eruptive boiling may be predicted classically with nano-sized cavities that are consistent with the measured surface roughness.     

Experimental investigation on heat transfer characteristics of low mass flux rifled tube with upward flow

An experiment for heat transfer of water flowing in a vertical rifled tube was conducted at subcritical and supercritical pressure. The main purpose is to explore the heat transfer characteristics of the new-type rifled tube at low mass flux. Operating conditions included pressures of 12–30 MPa, mass flux of 232–1200 kg/(m² s), and wall heat fluxes of 133–719 kW/m². The heat transfer performance and wall temperature distribution at various operating conditions were captured in the experiment. In the present paper, the heat transfer mechanism of the rifled tube was analyzed, the effects of pressure, wall heat flux and mass flux on heat transfer were discussed, and corresponding empirical correlations were also presented. The experimental results exhibit that the rifled tube has an obvious enhancement in heat transfer, even at low mass flux. In comparison with a smooth tube, the rifled tube efficiently prevents Departure from Nucleate Boiling (DNB) and delays dryout at subcritical pressure, and also improves the heat transfer of supercritical water remarkably, especially near pseudo-critical point. An increase in pressure or wall heat flux impairs the heat transfer at both subcritical and supercritical pressure, whereas the increasing mass flux has a contrary effect.     

Post-CHF heat transfer during two-phase upflow boiling of R-407C in a vertical pipe

This paper reports a study of heat transfer in the post-critical heat flux (post-CHF) regime under forced convective upflow conditions in a uniformly heated vertical tube of 12.7 mm internal diameter and 3 m length. Experiments were conducted with non-azeotropic ternary refrigerant mixture R-407C for reduced pressures ranging from 0.37 to 0.75, mass flux values from 1200 to 2000 kg/m² s and heat flux from 50 to 80 kW/m². Data shows a considerable effect of system pressure on the post-CHF heat transfer coefficient for specified mass and heat fluxes. The post-CHF heat transfer coefficients for R-407C are compared with three existing correlations which are found to over predict the current data. A modified correlation to represent the experimental data for R-407C is presented.     

Critical heat flux on flow boiling of methanol–water mixtures in a diverging microchannel with artificial cavities

This study constitutes an experimental investigation into the convective boiling heat transfer and critical heat flux (CHF) of methanol–water mixtures in a diverging microchannel with artificial cavities. Flow visualization shows that bubbles are generally nucleated at both the artificial cavities and side walls of the channel. This confirms the proper functioning of such artificial cavities. Consequently, the wall superheat of the onset nucleate boiling is significantly reduced. Experimental results show that the boiling heat transfer and CHF are significantly influenced by the molar fraction (x_m) as well as the mass flux. The CHF increases with an increase in mass flux at the same molar fraction. On the other hand, the CHF increases slightly from x_m = 0 to 0.3, and then decreases rapidly from x_m = 0.3 to 1 at the same mass flux. The maximum CHF is reached at x_m = 0.3, particularly for a mass flux of 175 kg/m² s, due to the Marangoni effect. Flow visualization confirms that the Marangoni effect helps a region with a liquid film breakup persist to a higher heat flux, and therefore a higher CHF. Moreover, a new empirical correlation involving the Marangoni effect for the CHF on the flow boiling of methanol–water mixtures is developed. The present correlation prediction shows excellent agreement with the experimental data, and further confirms that the present correlation may predict the Marangoni effect on the CHF for the convective boiling heat transfer of binary mixtures.     

Flow boiling CHF enhancement with surfactant solutions under atmospheric pressure

Surfactant effect on CHF (critical heat flux) was determined during water flow boiling at atmospheric pressure in closed loop filled with solution of tri-sodium phosphate (TSP, Na₃PO₄ · 12H₂O). TSP was added to the containment sump water to adjust pH level during accident in nuclear power plants. CHF was measured for four different water surfactant solutions in vertical tubes, at different mass fluxes (100–500 kg/m² s) and two inlet subcooling temperatures (50 °C and 75 °C). Surfactant solutions (0.05–0.2%) at low mass flux (～100 kg/m² s) showed the best CHF enhancement. CHF was decreased at high mass flux (500 kg/m² s) compared to the reference plain water data. Maximum increase in CHF was about 48% as compared to the reference data. Surfactant caused a decrease in contact angle associated with an increase of CHF from surfactant addition.     

Experimental study of an ammonia–water bubble absorber using a plate heat exchanger for absorption refrigeration machines

The development of absorption chillers activated by renewable heat sources has increased due mainly to the increase in primary energy consumption that causes problems such as greenhouse gases and air pollution among others. These machines, which could be a good substitute for compression systems, could be used in the residential and food sectors which require a great variety of refrigeration conditions. Nevertheless, the low efficiency of these machines makes it necessary to enhance heat and mass transfer processes in the critical components, mainly the absorber, in order to reduce their large size.This study used ammonia–water as the working fluid to look at how absorption takes place in a plate heat exchanger operating under typical conditions of absorption chillers, driven by low temperature heat sources. Experiments were carried out using a corrugated plate heat exchanger model NB51, with three channels, where ammonia vapor was injected in bubble mode into the solution in the central channel. The results achieved for the absorption flux were in the range of 0.0025–0.0063 kg m^?2 s^?1, the solution heat transfer coefficient varied between 2.7 and 5.4 kW m^?2 K^?1, the absorber thermal load from 0.5 to 1.3 kW. In addition, the effect of the absorber operating conditions on the most significant efficiency parameters was analyzed. The increase in pressure, solution and cooling flow rates positively affect the absorber performance, on the other hand an increase in the concentration, cooling, and solution temperature negatively affects the absorber performance.     

Effect of pulse heating parameters on the microscale bubble dynamics at a microheater surface

We study the effects of pulse heating parameters on the micro bubble behavior of a platinum microheater (100 μm×20 μm) immersed in a methanol pool. The experiment covers the heat fluxes of 10–37 MW/m² and pulse frequencies of 25–500 Hz. The boiling incipience is initiated at the superheat limit of methanol, corresponding to the homogeneous nucleation. Three types of micro boiling patterns are identified. The first type is named as the bubble explosion and regrowth, consisting of a violent explosive boiling and shrinking, followed by a slower bubble regrowth and subsequent shrinking, occurring at lower heat fluxes. The second type, named as the bubble breakup and attraction, consists of the violent explosive boiling, bubble breakup and emission, bubble attraction and coalescence process, occurring at higher heat fluxes than those of the first type. The third type, named as the bubble size oscillation and large bubble formation, involves the initial explosive boiling, followed by a short periodic bubble growth and shrinking. Then the bubble continues to increase its size, until a constant bubble size is reached which is larger than the microheater length.     

Pressure drop characteristics of R134a during flow boiling in a single rectangular micro-channel

The pressure-drop characteristics during flow boiling in a single rectangular micro-channel with hydraulic diameter of 0.68 mm are presented. In the present study, pressure drop was studied at heat flux range of 7.63–49.46 kW/m², mass flux range of 600–1400 kg/m² s, and saturation temperature of 23, 27 and 31 °C. Experimental results indicated that the total pressure was dominated by frictional pressure drop. The increase of mass flux also increased the frictional pressure gradient, whereas the increase of saturation temperature reduced the frictional pressure gradient. In addition, heat flux also had an insignificant effect on the frictional the pressure gradient. A new correlation was also proposed for effective design of micro-channel heat exchanger.     

Experimental investigation on two-phase flow boiling heat transfer of five refrigerants in horizontal small tubes of 0.5, 1.5 and 3.0 mm inner diameters

An experimental investigation on two-phase flow boiling heat transfer with refrigerants of R-22, R-134a, R-410A, C₃H₈ and CO₂ in horizontal circular small tubes is presented. The experimental data were obtained over a heat flux range of 5–40 kW m^?2, mass flux range of 50–600 kg m^?2 s^?1, saturation temperature range of 0–15 °C, and quality up to 1.0. The test section was made of stainless steel tubes with inner diameters of 0.5, 1.5 and 3.0 mm, and lengths of 330, 1000, 1500, 2000 and 3000 mm. The experimental data were mapped on Wang et al. (1997) [5] and Wojtan et al. (2005) [6] flow pattern maps. The effects of mass flux, heat flux, saturation temperature and inner tube diameter on the heat transfer coefficient are reported. The experimental heat transfer coefficients were compared with some existing correlations. A new boiling heat transfer coefficient correlation that is based on a superposition model for refrigerants in small tubes is presented with 15.28% mean deviation and ?0.48% average deviation.     

Boiling of R134a inside a glass minichannel. A new statistical approach of flow pattern characterization based on flow visualization

A test rig to study R134a flow boiling inside mini and micro-channels has been constructed. The test section is made up of a glass tube and several ITO conductive layers as heaters. A novel image processing technique has been developed for the study of R134a flow boiling regimes. The software routine extracts the bubble contours, measures geometrical features of each frame and collects the data analytically and statistically. The results refer to mass flux between 20 and 122 kg/m² s and the heat flux between 200 and 45,000 W/m², at the saturation temperatures of 20–25 °C. The tube inner diameter is 4 mm and the heated length was globally of 320 mm, distributed in eight shorter heaters of 40 mm each. The main goals are the development of a method that, starting from the analysis of several parameters, is able to identify the flow pattern inside the tube, as well as the study of the effects of coalescence on the flow pattern development along the tube.The flow patterns have been identified from a statistical point of view and the “transition zone” has been quantitatively characterized. Part of the analysis is then devoted to the flow pattern variation along the test section. The experiments demonstrated that coalescence is a phenomenon that can be analyzed also in terms of a statistical approach and that the flow pattern variations are not only a function of the mass flux and the quality, but along the tube bubble coalescence and gravity effects have a role in the flow patterns appearance.