Adiabatic two-phase flow in rectangular microchannels with different aspect ratios: Part I – Flow pattern,pressure drop and void fraction

An aspect ratio is an important parameter for two-phase flow in a rectangular microchannel. To study the aspect ratio effect on the flow pattern, pressure drop and void fraction, experiments of adiabatic liquid water and nitrogen gas two-phase flow in rectangular microchannels were conducted. The widths and heights of rectangular microchannels are 510 μm × 470 μm, 608 μm × 410 μm, 501 μm × 237 μm and 503 μm × 85 μm. Therefore, the aspect ratios of the rectangular microchannels are 0.92, 0.67, 0.47 and 0.16; and the hydraulic diameters of the rectangular microchannels were 490, 490, 322 and 143 μm, respectively. Experimental ranges were liquid superficial velocities of 0.06–1.0 m/s and gas superficial velocities of 0.06–71 m/s. Visible rectangular microchannels were fabricated using a photosensitive glass. And pressure drop in microchannels was directly measured through embedded ports. The visualization of the flow pattern was carried out with a high-speed camera and a long distance microscope. Typical flow patterns in the rectangular microchannels observed in this study were bubble flow, transitional flow (multiple flow) and liquid ring flow. As the aspect ratio decreased, the bubble flow regime became dominant due to the confinement effect and the thickness of liquid film in corner was decreased. A void fraction in the rectangular microchannels has a linear relation with the volumetric quality. And the two-phase flow becomes homogeneous with decreasing aspect ratio owing to the reduction of the liquid film thickness. Like Zhang et al.’s [19] correlation, as the confinement number increased, the C-value in Lockhart and Martinelli correlation decreased. And a frictional pressure drop in the rectangular microchannels was highly related with the flow pattern.     

Thermo-hydrodynamics analysis of vapor–liquid two-phase flow in the flat-plate pulsating heat pipe

A three-dimensional unsteady model of vapor–liquid two-phase flow and heat transfer in a flat-plate pulsating heat pipe (FP-PHP) is developed and numerically analyzed to study the thermal-hydrodynamic characteristics in two different configurations of FP-PHPs. The thermo-hydrodynamics characteristics under steady unidirectional circulation condition of the studied FP-PHPs are numerically investigated and discussed. The results indicate that the bubbly flow, slug flow and semi-annular/annular flow occur in the FP-PHP under the condition of steady unidirectional circulation, when the adjacent tubes of the FP-PHP become ‘upheaders’ and ‘downcomers’ of working fluid. The periodical oscillations of fluid temperature and vapor volume fraction are observed to be synchronous, while the temperature oscillation amplitude at adiabatic section is larger than that at condenser section but less than that at evaporator section. The increases in the heat load lead to the high temperature level and small integral equivalent thermal resistance of the FP-PHP. Additionally, compared with the traditional FP-PHP with uniform channels, the FP-PHP with micro grooves incorporated in the evaporator section is effective for the heat transfer enhancement and possesses a smaller thermal resistance at high heat loads.     

Fluid flow and heat transfer characteristics of low temperature two-phase micro-channel heat sinks – Part 1: Experimental methods and flow visualization results

A new cooling scheme is proposed where the primary working fluid flowing through a micro-channel heat sink is pre-cooled to low temperature using an indirect refrigeration cooling system. Cooling performance was explored using HFE 7100 as working fluid and four different micro-channel sizes. High-speed video imaging was employed to help explain the complex interrelated influences of hydraulic diameter, micro-channel width, mass velocity and subcooling on cooling performance. Unlike most prior two-phase micro-channel heat sink studies, which involved annular film evaporation due high void fraction, the low coolant temperatures used in this study produced subcooled flow boiling conditions. Decreasing coolant temperature delayed the onset of boiling, reduced bubble size and coalescence effects, and enhanced CHF. Heat fluxes in excess of 700 W/cm² could be managed without burnout. Premature CHF occurred at low mass velocities and was caused by vapor flow reversal toward the inlet plenum. This form of CHF was eliminated by decreasing coolant temperature and/or increasing flow rate.     

Mathematical model for gas–liquid two-phase flow and biodegradation of a low concentration volatile organic compound (VOC) in a trickling biofilter

A theoretical model is established for predicting the biodegradation of a low concentration volatile organic compound (VOC) in a trickling biofilter. To facilitate the analysis, the packed bed is simplified to a series of straight capillary tubes covered by the biofilm in which the liquid film flow on the surface of biofilm and the gas core flow in the center of tube. The theoretical formulas to calculate liquid film thickness in the capillary tube are obtained by simultaneously solving a set of hydrodynamic equations representing the momentum transport behaviors of the gas–liquid two-phase flow under co-current flow and counter-current flow. Subsequently, the mass transport equations are respectively established for the gas core, liquid film, and biofilm with considering the mass transport resistance in the liquid film and biofilm, the biochemical reaction in the biofilm, and the limitation of oxygen to biochemical reaction. Meanwhile, the surface area of mass transport in the capillary tube is modified by introducing the active biofilm surface area, namely the specific wetted surface area available for biofilm formation. The predicted purification efficiencies of VOC waste gas are found to be in good agreement with the experimental data for the trickling biofilters packed with ?8 mm, ?18 mm, and ?25 mm ceramic spheres under the gas–liquid co-current flow mode and counter-current flow mode. It has been revealed that for a fixed inlet concentration of toluene, the purification efficiency of VOC waste gas decreases with the increase in the gas and liquid flow rate, and increases with the increase in the specific area of packed materials and the height of packed bed. Additionally, it is found that there is an optimal porosity of packed bed corresponding to the maximal purification efficiency.     

Prediction of wall shear for horizontal annular air–water flow

In this study, non-intrusive pressure drop, liquid base film thickness distribution, and wave behavior measurements have been obtained for 206 horizontal annular two-phase (air–water) flow conditions in 8.8, 15.1, and 26.3 mm ID tubes. Wall shear was correlated to within 8% by a friction factor involving flow quality and gas Reynolds number. This correlation was found to perform better than those available in the literature, including film roughness correlations, two-phase multiplier methods, and pure data fits. Among published relations, the Müller-Steinhagen and Heck correlation was found to be the most accurate, while the Lockhart–Martinelli correlation can be modified to provide reasonable results. The gas friction velocity is found to be similar to the disturbance wave velocity, which suggests that waves are important sources of shear.     

Graphite–carbon nanotube composite electrodes for all vanadium redox flow battery

The voltammetric behaviors of graphite (GP) and its composites with carbon nanotube (CNT) were studied in 5 M H₂SO₄ + 1 M VOSO₄ solution with cyclic voltammetry (CV), and the surface morphology of the composites was observed with scanning electron microscope (SEM). The results obtained from voltammetry show that the redox couples of V(IV)/V(V) and V(II)/V(III), as positive and negative electrodes of all vanadium flow liquid battery, respectively, have good reversibility but low current on the GP electrode, and the current can be improved by CNT. It is found from the observation of SEM that the CNT is dispersed evenly on the surface of sheet GP when they are mixed together. The best composition for the positive and the negative of all vanadium flow liquid battery determined by comparing voltammetric behavior of the composite electrodes with different content of CNT is 5:95 (w_CNT/w_GP) for both positive and negative electrodes. The activity of the composite electrode can be affected by the heat treatment of CNT. CNT treated at 200 °C gives better activity to the composite electrode.     

Numerical study of liquid-gas and liquid-liquid Taylor flows using a two-phase flow model based on Arbitrary-Lagrangian–Eulerian (ALE) formulation

The liquid-gas and liquid-liquid Taylor flows in circular capillary tubes are numerically studied using a mathematical model developed in the frame of Arbitrary-Lagrangian–Eulerian (ALE), where the interface is tracked so that the important interfacial curvature and forces for Taylor flow can be accurately estimated. It is found that for liquid-gas Taylor flow, thin film thickness predicted by the present numerical model agrees very well with the benchmark experimental data both in visco-capillary and visco-inertia flow regimes. Thin film thicknesses decreases first and then increases as Reynolds number (Re) increases at relatively large capillary numbers (Ca). With the increase of Ca, classical pressure drop correlations become inaccurate, because of strong internal circulation inside liquid slug, the appearance of waves at rear meniscus, as well as the deviation from semi-spherical shape of head meniscus. For liquid-liquid flow, when Ca is small, thin film thickness correlations for liquid-gas flow can be used since the disperse phase has negligible effects, while when Ca is relatively large, the viscosity ratio and density ratio of continuous phase to disperse phase become two additional influencing factors. The larger are the viscosity ratio and the density ratio, the thicker is the film thickness. Different from stagnant thin film in liquid-gas flow, the flow in thin film of liquid-liquid flow is not stagnant and has a large contribution to pressure drop. The numerical model developed in this study is shown to be a powerful and accurate tool to study both the liquid-gas and liquid-liquid Taylor flows.     

Adiabatic two-phase flow in rectangular microchannels with different aspect ratios: Part II – bubble behaviors and pressure drop in single bubble

One of the major flow patterns in a microchannel is an elongated bubble flow, which is similar to a long slug bubble. Behaviors and pressure drop for a single bubble in a rectangular microchannel were studied. Based on the experiments in Part I of this paper, data for liquid superficial velocities of 0.06–0.8 m/s, gas superficial velocities of 0.06–0.66 m/s and AR of 0.92, 0.67, 0.47 and 0.16 were analyzed. The velocity, length, number, and frequency of the single bubble in the rectangular microchannel were obtained from image processing based on a unit cell model. The bubble velocities were proportional to total superficial velocity. As the aspect ratio decreased, the portion of the bubble area increased due to the corner effect. New correlation of the bubble velocity for different aspect ratio was proposed. Also, bubble and liquid slug length, the number of the unit cell and bubble frequency were analyzed with different aspect ratios. The pressure drop for the single bubble in the rectangular microchannels was evaluated using the information of the bubble behavior. The pressure drop in the single elongated bubble was proportional to the bubble velocity. The pressure drop in the single elongated bubble in the rectangular microchannel increased as the aspect ratio decreased.     

Evolution of the two-phase flow in a vertical tube—decomposition of gas fraction profiles according to bubble size classes using wire-mesh sensors

The wire-mesh sensor developed by the Forschungszentrum Rossendorf produces sequences of instantaneous gas fraction distributions in a cross section with a time resolution of 1200 frames per second and a spatial resolution of about 2–3 mm. At moderate flow velocities (up to 1–2 m·s⁻¹), bubble size distributions can be obtained, since each individual bubble is mapped in several successive distributions. The method was used to study the evolution of the bubble size distribution in a vertical two-phase flow. For this purpose, the sensor was placed downstream of an air injector, the distance between air injection and sensor was varied. The bubble identification algorithm allows to select bubbles of a given range of the effective diameter and to calculate partial gas fraction profiles for this diameter range. In this way, the different behaviour of small and large bubbles in respect to the action of the lift force was observed in a mixture of small and large bubbles.     

Transitional flow inside enhanced tubes for fully developed and developing flow with different types of inlet disturbances: Part II–heat transfer

Due to efficiency demands, augmented tubes are often used in heat exchangers with the result that many heat exchangers operate in the transitional region of flow. Due to the paucity of data, however, no data exists for enhanced tubes in this region. This article, being the second of a two-part paper (Part I investigating adiabatic flow), presents experimental heat transfer and diabatic friction factor data for four horizontal enhanced tubes for fully developed and developing flow in the transition region with four different types of inlet geometries. Smooth tube data was used for comparison. It was found that, unlike results obtained for adiabatic flow in Part I, inlet disturbances had no effect on the critical Reynolds numbers, with transition occurring at a Reynolds number of approximately 2000 and ending at 3000. Correlations were developed to predict the heat transfer and friction factors for a wide range of flow regimes, from laminar to turbulent flow. The correlations predicted the heat transfer data on average with a mean absolute error of 9.5%, predicting 85% of the data to within 15%. The friction factor correlations predicted the data with a mean absolute error of 5.5%, predicting 96% of the data to within 20%.     

Fluid flow and heat transfer characteristics of low temperature two-phase micro-channel heat sinks – Part 2. Subcooled boiling pressure drop and heat transfer

This second part of a two-part study explores the performance of a new cooling scheme in which the primary working fluid flowing through a micro-channel heat sink is indirectly cooled by a refrigeration cooling system. The objective of this part of study is to explore the pressure drop and heat transfer characteristics of the heat sink. During single-phase cooling, pressure drop decreased with increasing heat flux because of decreased liquid viscosity. However, pressure drop began increasing with increasing heat flux following bubble departure. These opposite trends produced a minimum in the variation of pressure drop with heat flux. Increasing liquid subcooling decreased two-phase pressure drop because of decreased void fraction caused by strong condensation at bubble interfaces as well as decreased likelihood of bubble coalescence. It is shown macro-channel subcooled boiling pressure drop and heat transfer correlations are unsuitable for micro-channel flows. However, two new modified correlations produced good predictions of the present heat transfer data.     

High heat flux flow boiling in silicon multi-microchannels – Part III: Saturated critical heat flux of R236fa and two-phase pressure drops

New experimental critical heat flux results for saturated boiling conditions have been obtained for R236fa flowing in a silicon multi-microchannel heat sink composed of 67 parallel channels, 223 μm wide, 680 μm high and with 80 μm thick fins separating the channels. The microchannel length was 20 mm. The footprint critical heat fluxes measured varied from 112 to 250 W/cm² and the wall critical heat fluxes from 21.9 to 52.2 W/cm² for mass velocities from 276 to 992 kg/m²s. When increasing the mass velocity, the wall critical heat flux was observed to increase. The inlet saturation temperatures (20.31 ? T_sat,in ? 34.27 °C) and the inlet subcoolings (0.4 ? Δ T_sub ? 15.3 K) were found to have a negligible influence on the saturated CHF. The best methods for predicting the data were those of Wojtan et al. [L. Wojtan, R. Revellin, J. R. Thome, Investigation of critical heat flux in single, uniformly heated microchannels, Exp. Therm. Fluid Sci. 30 (2006) 765–774] and Revellin and Thome [R. Revellin, J. R. Thome, A theoretical model for the prediction of the critical heat flux in heated microchannels, Int. J. Heat Mass Transfer 50 (in press)]. They both predict the experimental CHF results with a mean absolute error of around 9%. Using the critical vapour quality, an annular-to-dryout transition is also proposed as a limit in a diabatic microscale flow pattern map. Pressure drop measurements were measured and analysed, showing that the homogeneous model could correctly predict the observed trends.     

A high-resolution Navier–Stokes solver for direct numerical simulation of free shear flow

Abstract

A high-resolution, Navier–Stokes solver is developed for direct numerical simulation (DNS) of free shear flow. All terms in Navier–Stokes equations are discretized using higher order methods. Diffusion term is discretized using fourth order central difference scheme while second order Adams–Bashforth is used for time derivative. Advecting velocity is approximated using fourth order Lagrangian interpolation. For the approximation of advected velocity, a blended fifth order-upwind scheme is proposed. Developed high resolution solver is used for DNS of round jet in transitional and turbulent regimes. A novel open outlet boundary condition (OOBC) is proposed which has the ability to dynamically adjust according to prevailing local condition at the outlet thereby minimizing reflections from outlet. Ability of blended fifth order upwind scheme and fifth order WENO is assessed in terms of algorithmic efficiency as well as fidelity of simulations. It is demonstrated that the proposed blended fifth order upwind scheme outperforms the WENO scheme in terms of algorithmic efficiency. Assessment of fidelity of simulations reveals that WENO displays a tendency to over-predict momentum advection in transitional as well as fully turbulent regime of the round jet. In contrast, the proposed advection scheme is not faced with such limitation.     

Transitional flow inside enhanced tubes for fully developed and developing flow with different types of inlet disturbances: Part I – Adiabatic pressure drops

Due to tube enhancements being used to achieve higher process efficiencies, heat exchangers are starting to operate in the transition region of flow. The paucity of data, however, has the implication that no correlation exists for enhanced tube transition flow. This article, being the first of a two-part paper, presents adiabatic friction factor data for four enhanced tubes for fully developed and developing flow in the transition region. Three inlets were used for developing flows, namely square-edged, re-entrant and bellmouth inlets. It was found that, as in the case of smooth tubes, transition was affected by the type of inlet used, with transition being delayed the most for the smoothest inlet. Correlations were developed to predict the fully developed critical Reynolds numbers and friction factors in the transition region. The correlations predicted the critical Reynolds numbers on average to within 1% with a root mean square deviation of less than 8%, while transition friction factors were predicted with a mean absolute error of 6.6%, predicting 89% of the data to within a 15% error.     

A one-dimensional,two-phase model for direct methanol fuel cells – Part I: Model development and parametric study

A one-dimensional, steady-state, two-phase direct methanol fuel cell (DMFC) model is developed to precisely investigate complex physiochemical phenomena inside DMFCs. In this model, two-phase species transport through the porous components of a DMFC is formulated based on Maxwell–Stefan multi-component diffusion equations, while capillary-induced liquid flow in the porous media is described by Darcy's equation. In addition, the model fully accounts for water and methanol crossover through the membrane, which is driven by the effects of electro-osmotic drag, diffusion, and the hydraulic pressure gradient. The developed model is validated against readily available experimental data in the literature. Then, a parametric study is carried out to investigate the effects of the operating temperature, methanol feed concentration, and properties of the backing layer. The results of the numerical simulation clarify the detailed influence of these key designs and operating parameters on the methanol crossover rate as well as cell performance and efficiency. The results emphasize that the material properties and design of the anode backing layer play a critical role in the use of highly concentrated methanol fuel in DMFCs. The present study forms a theoretical background for optimizing the DMFC's components and operating conditions.     

New prediction methods for CO2 evaporation inside tubes: Part II—An updated general flow boiling heat transfer model based on flow patterns

Corresponding to the updated flow pattern map presented in Part I of this study, an updated general flow pattern based flow boiling heat transfer model was developed for CO₂ using the Cheng–Ribatski–Wojtan–Thome [L. Cheng, G. Ribatski, L. Wojtan, J.R. Thome, New flow boiling heat transfer model and flow pattern map for carbon dioxide evaporating inside horizontal tubes, Int. J. Heat Mass Transfer 49 (2006) 4082–4094; L. Cheng, G. Ribatski, L. Wojtan, J.R. Thome, Erratum to: “New flow boiling heat transfer model and flow pattern map for carbon dioxide evaporating inside tubes” [Heat Mass Transfer 49 (21–22) (2006) 4082–4094], Int. J. Heat Mass Transfer 50 (2007) 391] flow boiling heat transfer model as the starting basis. The flow boiling heat transfer correlation in the dryout region was updated. In addition, a new mist flow heat transfer correlation for CO₂ was developed based on the CO₂ data and a heat transfer method for bubbly flow was proposed for completeness sake. The updated general flow boiling heat transfer model for CO₂ covers all flow regimes and is applicable to a wider range of conditions for horizontal tubes: tube diameters from 0.6 to 10 mm, mass velocities from 50 to 1500 kg/m² s, heat fluxes from 1.8 to 46 kW/m² and saturation temperatures from ?28 to 25 °C (reduced pressures from 0.21 to 0.87). The updated general flow boiling heat transfer model was compared to a new experimental database which contains 1124 data points (790 more than that in the previous model [Cheng et al., 2006, 2007]) in this study. Good agreement between the predicted and experimental data was found in general with 71.4% of the entire database and 83.2% of the database without the dryout and mist flow data predicted within ±30%. However, the predictions for the dryout and mist flow regions were less satisfactory due to the limited number of data points, the higher inaccuracy in such data, scatter in some data sets ranging up to 40%, significant discrepancies from one experimental study to another and the difficulties associated with predicting the inception and completion of dryout around the perimeter of the horizontal tubes.     

Induction for multiple rotating detonation waves in the hydrogen–oxygen mixture with tangential flow

Rotating detonation engines are studied more and more widely because of high thermodynamic efficiency and high specific impulse. Generally one detonation wave exists in the engines but sometimes multiple detonation waves appear, as is complicated and difficult to explain. Increasing the number of rotating detonation waves uniforms the flow field and weakens the combustion instabilities. A controllable way to induce multiple detonation waves is introduced here. Rotating detonation engine runs with a single detonation wave or multiple detonation waves were both conducted. Pressure sensors were used to record the pressure traces of rotating detonation waves and gas flow controllers controlled the flow rates of reactants. Tangential flow of reactants from the predetonator produces shock waves moving upstream, inducing multiple rotating detonation waves when there is axial flow of reactants from the head of the combustor. The maximum number of detonation waves is subject to the flow rates.