Generic features and puzzles of nucleate boiling

At high reduced pressures extremely high nucleate boiling heat transfer coefficients (HTC) were measured. A single mechanism, which presents a consistent explanation of such HTCs, is very high intensity of liquid evaporation at the periphery of dry spots (nucleation sites) at the heated wall. Due to very small size the nucleation sites can be considered as point heat sinks. Between them convective heat transfer occurs, which in its turn is governed by the inherent mechanisms of boiling. The above two mechanisms comprise a total heat flux from the heated wall in nucleate boiling. The predicting equation, which determines heat flux in boiling via the wall superheat and liquid properties, has been developed with accuracy to two universal numerical factors fitted to the experimental data. Although the equation developed is found to be in good agreement with numerous experimental data for different liquids and in the wide range of reduced pressures and heat fluxes there exists a problem in nucleate boiling, which has not been understood to the full even qualitatively. This problem is the dependence of nucleation site density on the physical properties of the liquid and on the controlling parameters. Some new experimental results by Theofanous et al. [T.G. Theofanous, T.N. Dinh, J.P. Tu, A.T. Dinh, The boiling crisis phenomenon. Part I: Nucleation and nucleate boiling heat transfer, Exp. Therm. Fluid Sci. 26 (2002) 775–792; T.G. Theofanous, T.N. Dinh, J.P. Tu, A.T. Dinh, The boiling crisis phenomenon. Part II: Dryout dynamics and burnout, Exp. Therm. Fluid Sci. 26 (2002) 793–810.] and Qi et al. [Y. Qi, J.F. Klausner, R. Mei, Role of surface structure in heterogeneous nucleation, Int. J. Heat Mass Transfer 47 (2004) 3097–3107; Y. Qi, J.F. Klausner, Heterogeneous nucleation with artificial cavities, J. Heat Transfer 127 (2005) 1189–1196; Y. Qi, J.F. Klausner, Comparison of nucleation site density for pool boiling and gas nucleation, J. Heat Transfer 128 (2006) 13–20.] require revising the traditional views on a nature of the active nucleation sites in boiling. These results remind the old question: why can the nucleation sites arise at low superheats of the absolutely wettable surface? Obtaining theoretical equation for nucleation site density remains the most significant challenge in nucleate boiling theory.     

Experimental Study of Boiling Heat Transfer on Multiple and Single Nucleation Sites Using a Boiling-Meter

The general objective of this study is to contribute to a better understanding of heat transfer in a nucleate boiling regime. The aim is to determine the heat transfer characteristics under controlled operating conditions (thermodynamics of the fluid, noncondensable gas, surface state). Experimental investigations have been carried out in natural convection and nucleate boiling regimes. An experimental device was realized to perform boiling experiments using a boiling-meter, allowing investigations for different orientations of the wall. The boiling-meter is designed to investigate boiling for single and multiple nucleation sites. The purpose of this paper is to detail the experimental setup as well as the boiling-meter. This device allows the determination of the temporal heat transfer characteristics evolutions. In particular, this new device allows bringing to light the phenomenon of nucleation, growth, and detachment of generated vapor bubbles on a single artificial nucleate site, as well as for multiple natural nucleation sites. First results of the influence of the orientation of the heating wall for multiple and single nucleation sites on heat transfer are presented and analyzed.     

Enhancement of nucleate boiling on composite surfaces

A composite heating surface composed of materials with different thermal conductivities can be expected to enhance heat transfer in nucleate boiling. This is because the end surface, with higher conductivity, will attain a higher temperature and as a result will serve to provide preferential nucleation sites. To confirm this idea, several composite surfaces were fabricated by uniaxially imbedding thin copper cylinders in the heat flow direction on a stainless steel circular plate 30 mm in diameter and 5 mm thick. The imbedded copper cylinders ranged from 1 mm to 4 mm in diameter and one to 77 in number. The heat transfer performance of these composite surfaces was investigated for pool boiling of saturated water at atmospheric pressure. It was confirmed that the copper cylinder surfaces exposed to water functioned as local hot spots to initiate preferential nucleate boiling, leading to higher boiling heat transfer coefficients than those on a homogeneous stainless steel surface. The measured void fraction above the heating surface verified intensive bubble generation on the surface of the copper cylinders. This situation continued up to a certain heat flux level and was then followed by nucleation on the mother surface of stainless steel around the copper cylinders. A numerical analysis of heat conduction within a composite wall simulated the temperature distribution within the wall and the variation in surface heat flux at the time of boiling incipience. © 1998 Scripta Technica, Heat Trans Jpn Res, 27(3): 216–228, 1998     

Spatio-temporal analysis of nucleate pool boiling: identification of nucleation sites using non-orthogonal empirical functions

The analysis of spatio-temporal data and the physical understanding of the systems generating them are often limited by the available techniques. These limitations are especially evident in nucleate boiling. This paper investigates the analysis of a sequence of temperature fields obtained from a pool nucleate boiling experiment. Spatio-temporal data for the wall temperature in pool nucleate boiling of water on a thin, horizontal, stainless steel plate were obtained by liquid crystal thermography and high speed video recording. A previous analysis provided examples of the thermal conditions for activation of individual nucleation sites, for the heat transfer mechanisms during bubble growth and for the consequent interactions between adjacent sites. Principal component analysis (PCA) is shown to provide a reconstruction of the temperature fields that is accurate in the root mean square sense but which obscures information about the underlying physics, such as positions of the nucleation sites. In contrast, a new approach using non-orthogonal empirical functions (NEFs) encodes the relevant physical constraints (e.g., each NEF has a radially symmetrical form as suggested by the pattern of cooling during bubble growth). NEFs provide an efficient identification of the positions of active sites in successive frames; they are better suited to the analysis of non-stationary dynamics than PCA and allow for information compression.     

Lateral coalescence of bubbles in the presence of a DC electric field

In this work, the influence of electrohydrodynamic forces on lateral bubble coalescence during nucleate pool boiling is investigated. An experimental pool boiling test facility was used with n-pentane as the working fluid. Boiling took place atop a polished copper surface on which two artificial nucleation sites were fabricated. The nucleation sites were 180 μm in diameter and 500 μm deep with a centre-to-centre spacing of 660 μm. Two diametrically opposed windows allowed for illumination and high speed videography of the bubble growth process from the two nucleation sites. For the saturated boiling tests considered here, bubbles only formed at the two artificial nucleation sites allowing their coalescence behaviour to be scrutinized. A screen electrode above the boiling surface and a high voltage DC power supply facilitated the establishment of the electric field which was varied between 0 and 34.5 kVcm^− 1. Observation of the high speed videos has revealed that bubble coalescence is influenced in such a way that it is delayed in the presence of the electric field to such an extent that, at the highest electric field strength tested, it is avoided all together. To help explain the observed results, a simple numerical model is solved showing that bubbles in close proximity to one another create an electric field distribution with high intensity between them. The overall result is net polarization forces that push the bubbles apart, and the closer they are together the larger this repulsive force becomes.     

Numerical prediction of critical heat flux in pool boiling with the two-fluid model

Three-dimensional numerical simulations of the atmospheric saturated pool boiling are performed with the aim of predicting the critical heat flux. The two-phase mixture in pool boiling is described with the transient two-fluid model. The transient heat conduction in the horizontal heated wall is also solved. Dynamics of vapor generation on the heated wall is modeled through the density of nucleation sites and the bubble residence time on the wall. The heater’s surface is divided into zones, which number per unit area equals the density of nucleation sites, while the location of nucleation site within each zone is determined by a random function. The results show a replenishment of the heater’s surface with water and surface wetting for lower heat fluxes, while heater’s surface dry-out is predicted at critical heat flux values. Also, it is shown that the decrease of nucleation site density leads to the reduction of critical heat flux values. Obtained results of critical heat flux are in good agreement with available measured data. The presented approach is original regarding both the application of the two-fluid two-phase model for the prediction of boiling crisis in pool boiling and the defined boundary conditions at the heated wall surface.     

Phase change phenomena in silicon microchannels

Understanding the boiling process and two-phase flow behavior in microchannels is the key to developing microchannel heat sinks for high-power microprocessors. We conducted experiments in micromachined silicon channels with a range of 27-171 μm hydraulic diameters and varying surface roughnesses. Bubble nucleation, flow patterns, wall temperature, as well as transient pressure fluctuations were recorded and analyzed. We observed both typical nucleate boiling and eruption boiling with large amounts of wall superheat in these channels, and recorded up to 138 kPa transient pressure fluctuations due to bubble nucleation. We found the boiling mechanism is strongly dependent on the wall surface roughness, and we explained the boiling mechanism in sub-150 μm diameter channels with Hsu’s model.     

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.     

A thermodynamic analysis for heterogeneous boiling nucleation on a superheated wall

A thermodynamic model based on Gibbs free energy and availability is developed for onset of heterogeneous nucleation on heated surfaces with different wettabilities in pool boiling. Different from classical nucleation theory, this model takes into consideration the temperature gradient in the superheated liquid layer adjacent to the wall as well as the contact angle between the liquid and the wall. Using Gibbs free energy equilibrium condition, a closed form solution is obtained on the critical radius for onset of heterogeneous boiling nucleation on walls with different wettabilities. Effects of contact angles and wall temperatures on the critical radius, the wall temperature gradient of the superheated liquid layer and the heat flux at onset of heterogeneous nucleate boiling are illustrated. These effects on the change of availability during the heterogeneous nucleation process, representing the energy barrier for the occurrence of the first-order phase transition, are also discussed.     

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

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

Numerical Investigation of Saturated Flow Boiling in Microchannels by the Lattice Boltzmann Method

Bubble formation in saturated flow boiling in 2D microchannels, generated from a microheater under constant wall heat flux or constant wall temperature conditions, is studied numerically based on a newly developed lattice Boltzmann model for liquid-vapor phase change. Simulations are carried out to study effects of inlet velocity, contact angle, and heater size on saturated flow boiling of water under constant wall heat flux conditions. Important information, such as effects of static contact angle on nucleation time and nucleation temperature, which was unable to be obtained by other numerical simulation methods, is obtained. Furthermore, effects of inlet velocity, contact angle, and superheat on nucleate boiling heat transfer in steady flow boiling of water under constant wall temperature conditions are also presented. It is found that the nucleate boiling heat transfer at the microheater is higher if the heater surface is more hydrophilic, because the superheated vapor at the hydrophilic wall has a thinner thermal boundary layer and a larger thermal conductivity.     

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.     

Numerical simulation of nucleate boiling on a horizontal surface at high heat fluxes

Nucleate boiling at high heat fluxes has been studied numerically by solving the equations governing conservation of mass, momentum and energy in the liquid and vapor phases. The interface is captured by using the level set method based on a sharp-interface representation. The evaporative heat flux from the liquid microlayer is incorporated in the analysis. The effects of wall superheat, number density of nucleation sites and waiting period on the bubble dynamics and heat transfer in nucleate boiling are investigated. The heat fluxes obtained from the present numerical simulations are compared with the experimental data reported in the literature.     

Nucleation site interaction between artificial cavities during nucleate pool boiling on silicon with integrated micro-heater and temperature micro-sensors

Nucleate boiling is commonly characterised as a very complex and elusive process. Many involved mechanisms are still not fully understood and more detailed consideration is needed. In this study, bubble growth from micro-fabricated artificial cavities with varied spacing on a horizontal 380 μm thick silicon wafer was investigated. The horizontally oriented boiling surface was heated by a thin resistance heater integrated on the rear of the silicon test section. The temperature was measured using 16 integrated micro-sensors situated on the boiling surface, each with an artificial cavity located in its geometrical centre. Experiments with three different spacings 1.5, 1.2 and 0.84 mm in between cavities with a nominal mouth diameter of 10 μm and a depth of 80 μm were undertaken. To conduct pool boiling experiments, the test section was mounted inside a closed stainless steel boiling chamber with optical access and completely immersed in degassed fluorinert FC-72. Bubble nucleation, growth and detachment at 0.5 and 1 bar absolute pressure were investigated using high-speed imaging. The effect of decreasing inter-site distance on bubble nucleation frequency, bubble departure frequency and diameter with increasing wall superheat is presented. Furthermore, the frequency of horizontal bubble coalescence was determined. The regions of influence on the measured frequencies and bubble departure diameter were compared with recently published findings.     

A new comprehensive model for nucleate pool boiling heat transfer of pure liquid at low to high heat fluxes including CHF

Based on the fractal distribution of nucleation sites present on heating surfaces, a new comprehensive model is developed for the nucleate pool boiling of pure liquid at low to high heat fluxes including the critical heat flux (CHF). The proposed model is expressed as a function of total number, minimum and maximum sizes of active nucleation sites, fractal dimension, superheat temperature, and properties of fluids. No additional empirical constant is introduced in the proposed model. This fractal model contains less empirical constants than the conventional models. The model predictions are in good agreement with the available experimental data.     

Effect of surface condition on boiling heat transfer from silicon chip with submicron-scale roughness

Boiling heat transfer on treated silicon surfaces was studied. Experiments were conducted to investigate the effects of submicron-scale roughness on the boiling heat transfer at a subcooled condition in FC-72 at the ambient pressure. Two-type of treated silicon surfaces were prepared for boiling surfaces using anodisation with HF (hydrofluoric acid) based electrolyte and DMF (dimethylforamide) based one. The back side of the treated surface was glued to the back side of the other silicon chip on which thin film heaters and thin film temperature sensors were fabricated using conventional MUPs processes with doped polysilicon. The treated chips with submicron-scale roughness which provide many possible nucleation sites showed considerable enhancement in the nucleate boiling heat transfer coefficients compared to the untreated silicon surface. Further, the critical heat flux (CHF) of the treated surfaces increase linearly to the increase in the effective area for boiling.     

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.     

Numerical Simulation of Bubbles Deformation,Flow, and Coalescence in a Microchannel Under Pseudo-Nucleation Conditions

This paper reports the results of numerical study on bubbles deformation, flow, and coalescence under pseudo-nucleate boiling conditions in horizontal mini-/microchannels. The numerical simulation, which is based on the multiphase model of volume of fluid method, aims to study the corresponding flow behaviors of nucleate bubbles generated from the tube walls in mini-/microchannels so as to understand the effect of confined surfaces/walls on nucleate bubbles and heat transfer. Under the pseudo- or quasi-nucleate boiling condition, superheated small vapor bubbles are injected at the wall to ensure that the bubbles generation is under a similar condition of real nucleation. The numerical study examined the fluid mechanics of bubble motion with heat transfer, but the mass transfer across the bubble–liquid interface is not simulated in the present work.     

A fractal model for critical heat flux in pool boiling

In this paper, a fractal model for the high heat flux nucleate boiling region and for the critical heat flux (CHF) is proposed. The expression for the critical heat flux (CHF) is derived based on the fractal distribution of nucleation sites on boiling surfaces. The proposed fractal model for CHF is found to be a function of wall superheat, the contact angle and physical properties of fluid. The relation between CHF and the number of active nucleation sites is obtained from the fractal distribution of active nucleation sites on boiling surfaces. The contact angle and the physical properties of fluid have the important effects on CHF. The predicted CHF from a boiling surface based on the proposed fractal model is compared with the existing experimental data. An excellent agreement between the proposed model predictions and experimental data is found.     

Bubble Dynamics and Heat Transfer During Pool Boiling on Wettability Patterned Surfaces

Surfaces with spatial wettability patterns have been proven to enhance heat transfer coefficient and critical heat flux in pool boiling. To understand the physical mechanism behind this phenomenon and obtain the correlation among some critical parameters (bubble departure frequency, bubble size, nucleation site density, surface tension), pool boiling experiments were conducted. A Pyrex glass with a layer of indium-tin-oxide was used as the substrate. Hydrophobic patterns will serve as nucleation sites. Experiments were conducted in deionized water under atmospheric pressure at a relatively low heat flux. The processes of nucleation, growth, and departure of individual bubbles were visualized by using a high speed camera through the bottom of the heater surface. It has been found that the patterned surface performed the best in heat transfer for subcooled pool boiling when compared with hydrophilic and hydrophobic surfaces. The nucleation site density of the biphilic surface was much higher, when compared with that of the homogeneous surface. The individual bubbles always nucleate on the edge of the hydrophobic and hydrophilic area, and then move onto the hydrophobic pattern. Most of the individual bubbles detach from the wettability patterned surface in the diameter range from 300 µm to 450 µm (around 77.3%). The bubble departure periods scatter in the range from 80 ms to 1500 ms.