Determination of annular condensation heat transfer coefficient of steam in microchannels with trapezoidal cross sections

Experiments have been carried out to determine annular condensation heat transfer coefficient of steam in two silicon microchannels having trapezoidal cross sections with the same aspect ratio of 3.15 at 54 < G < 559 kg/m² s under 3-side cooling conditions. A semi-analytical method, based on turbulent flow boundary layer theory of liquid film with correlations of pressure drop and void fraction valid for microchannels, is used to derive the annular local condensation heat transfer coefficients. The predicted values based on the semi-analytical model are found within ±20% of 423 data points. It is shown that the annular condensation heat transfer coefficient in a microchannel increases with mass flux and quality and decreases with the hydraulic diameter.     

Flow condensation in parallel micro-channels – Part 2: Heat transfer results and correlation technique

This second part of a two-part study concerns heat transfer characteristics for FC-72 condensing along parallel, square micro-channels with a hydraulic diameter of 1 mm, which were formed in the top surface of a solid copper plate. Heat from the condensing flow was rejected to a counter flow of water through channels brazed to the underside of the copper plate. The FC-72 condensation heat transfer coefficient was highest near the channel inlet, where the annual liquid film is thinnest. The heat transfer coefficient decreased along the micro-channel because of the film thickening and eventual collapse of the annular regime. Notable heat transfer enhancement was observed for annular flow regions of the micro-channel associated with interfacial waves. Comparing the present data to predictions of previous annular condensation heat transfer correlations shows correlations intended for macro-channels generally provide better predictions than correlations intended specifically for mini/micro-channels. A new condensation heat transfer coefficient correlation is proposed for annular condensation heat transfer in mini/micro-channels. The new correlation shows excellent predictive capability based on both the present FC-72 data and a large database for mini/micro-channel flows amassed from eight previous sources.     

Flow condensation in parallel micro-channels – Part 1: Experimental results and assessment of pressure drop correlations

In this first part of a two-part study, experiments were performed to investigate condensation of FC-72 along parallel, square micro-channels with a hydraulic diameter of 1 mm and a length of 29.9 cm, which were formed in the top surface of a solid copper plate. The condensation was achieved by rejecting heat to a counter flow of water through channels brazed to the underside of the copper plate. The FC-72 entered the micro-channels slightly superheated, and operating conditions included FC-72 mass velocities of 68–367 kg/m² s, FC-72 saturation temperatures of 57.2–62.3 °C, and water mass flow rates of 3–6 g/s. Using high-speed video imaging and photomicrographic techniques, five distinct flow regimes were identified: smooth-annular, wavy-annular, transition, slug, and bubbly, with the smooth-annular and wavy-annular regimes being most prevalent. A detailed pressure model is presented which includes all components of pressure drop across the micro-channel. Different sub-models for the frictional and accelerational pressure gradients are examined using the homogenous equilibrium model (with different two-phase friction factor relations) as well as previous macro-channel and mini/micro-channel separated flow correlations. Unexpectedly, the homogenous flow model provided far more accurate predictions of pressure drop than the separated flow models. Among the separated flow models, better predictions were achieved with those for adiabatic and mini/micro-channels than those for flow boiling and macro-channels.     

Experimental investigation of convective heat transfer coefficient during downward laminar flow condensation of R134a in a vertical smooth tube

This paper presents an experimental investigation of laminar film condensation of R134a in a vertical smooth tube having an inner diameter of 7–8.1 mm and a length of 500 mm. Condensation experiments were performed at mass fluxes of 29 and 263 kg m^?2 s^?1. The pressures were between 0.77 and 0.1 MPa. The heat transfer coefficient, film thickness and condensation rate during downward condensing film were determined. The results show that an interfacial shear effect is significant for the laminar condensation heat transfer of R134a under the given conditions. A new correlation for the condensation heat transfer coefficient is proposed for practical applications.     

Effects of heat flux,vapour quality,channel hydraulic diameter on flow boiling heat transfer in variable aspect ratio micro-channels using transparent heating

Experiments on flow boiling heat transfer in high aspect ratio micro-channels with FC-72 were carried out. Three channels with different hydraulic diameters (571, 762 and 1454 μm) and aspect ratios (20, 20 and 10) were selected. The tested mass fluxes were 11.2, 22.4 and 44.8 kg m^?2 s^?1 and heat fluxes ranging from 0–18.6 kW m^?2. In the present study, boiling curves with obvious temperature overshoots are presented. Average heat transfer coefficient and local heat transfer coefficient along stream-wise direction are measured as a function of heat flux and vapour quality respectively. Slug-annular flow and annular flow are the main flow regimes. Convective boiling is found to be the dominant heat transfer mechanism. Local heat transfer coefficient increases with decreasing hydraulic diameter. Moreover, the effect of hydraulic diameter is more significant when mass flux is higher. The unique channel geometry is considered as the decisive reason of the flow regimes as well as heat transfer mechanisms.     

Pressure drop studies on two-phase flow in a uniformly heated vertical tube at pressures up to the critical point

Measurements of two-phase flow pressure drop have been made during a phase-change heat transfer process with refrigerant (R-134a) as a working fluid for a wide range of pressures right up to the critical pressure. The experiments were conducted in a uniformly heated vertical tube of 12.7 mm internal diameter and 3 m length over a heat flux range of 35–80 kW/m², mass flux range of 1200–2000 kg/m² s, exit quality range of 0.19–0.81 and for reduced pressures ranging from 0.24 to 1 with a fixed inlet subcooling of 3 °C. The measurements were compared with the predictions from the homogeneous flow model, a separated flow model using correlations drawn from the literature for void fraction and frictional pressure drop, and finally, using a flow pattern-based predictive method accounting specifically for bubbly, slug and annular flow regimes. It was found that the best results were obtained with the flow pattern-based approach with a mean deviation of ±20% over the entire pressure range.     

A complete evaluation method for the experimental data of flow boiling in smooth tubes

A complete solution for boiling phenomena in smooth tubes has been giving as a procedure regarding with the calculation of convective heat transfer coefficient and pressure drop using accurate experimental data validated by flow regime maps and sight glasses on the experimental facility. The experimental study is conducted in order to investigate the effect of operating parameters on flow boiling convective heat transfer coefficient and pressure drop of R134a. The smooth tube having 8.62 mm inner diameter and 1100 mm length is used in the experiments. The effect of mass flux, saturation temperature and heat flux is researched in the range of 290–381 kg/m² s, 15–22 °C and 10–15 kW/m², respectively. The experiments revealed that the heat transfer coefficient and pressure drop are significantly affected by mass flux for all tested conditions. Moreover, the experimental results are compared with well-known heat transfer coefficient and frictional pressure drop correlations given in the literature. In addition, 122 number of heat transfer and pressure drop raw experimental data is given for researchers to validate their theoretical models.     

Condensation heat transfer and pressure drop of HFC-134a in a helically coiled concentric tube-in-tube heat exchanger

The two-phase heat transfer coefficient and pressure drop of pure HFC-134a condensing inside a smooth helically coiled concentric tube-in-tube heat exchanger are experimentally investigated. The test section is a 5.786 m long helically coiled double tube with refrigerant flowing in the inner tube and cooling water flowing in the annulus. The inner tube is made from smooth copper tubing of 9.52 mm outer diameter and 8.3 mm inner diameter. The outer tube is made from smooth copper tubing of 23.2 mm outer diameter and 21.2 mm inner diameter. The heat exchanger is fabricated by bending a straight copper double-concentric tube into a helical coil of six turns. The diameter of coil is 305 mm. The pitch of coil is 35 mm. The test runs are done at average saturation condensing temperatures ranging between 40 and 50 °C. The mass fluxes are between 400 and 800 kg m⁻² s⁻¹ and the heat fluxes are between 5 and 10 kW m⁻². The pressure drop across the test section is directly measured by a differential pressure transducer. The quality of the refrigerant in the test section is calculated using the temperature and pressure obtained from the experiment. The average heat transfer coefficient of the refrigerant is determined by applying an energy balance based on the energy rejected from the test section. The effects of heat flux, mass flux and, condensation temperature on the heat transfer coefficients and pressure drop are also discussed. It is found that the percentage increase of the average heat transfer coefficient and the pressure drop of the helically coiled concentric tube-in-tube heat exchanger, compared with that of the straight tube-in-tube heat exchanger, are in the range of 33–53% and 29–46%, respectively. New correlations for the condensation heat transfer coefficient and pressure drop are proposed for practical applications.     

Condensation heat transfer and pressure drop of R134a in annular helicoidal pipe at different orientations

Experimental investigations were conducted to determine the condensation heat transfer and pressure drop of refrigerant R134a in annular helicoidal pipe at three inclination angles. The experiments were performed with the Reynolds number of R134a ranging from 60 to 200, and that of cooling water from 3600 to 22 000; temperatures of R134a at 30 °C and 35 °C, and cooling water at 16 °C, 20 °C and 24 °C. The experimental results indicated that the refrigerant Nusselt number was larger at lower refrigerant saturation temperature, and would increase with the increase of mass flow rates of refrigerant and cooling water. It was found that the refrigerant heat transfer coefficient of annular helicoidal pipe could be two times larger than that of equivalent plain straight pipe when the refrigerant Reynolds number was larger than 140. Comparison with identical helicoidal pipe with opposite flow channel arrangement revealed that the refrigerant heat transfer rate was larger when the refrigerant was flowing in the annular section at the cooling water Reynolds number larger than 4000, but the pressure drop was always larger in this flow channel arrangement.     

Comparative investigations of the condensation of R134a and R404A refrigerants in pipe minichannels

The present paper describes the results of experimental investigations of heat transfer and pressure drop during the condensation of the R134a and R404A refrigerants in pipe minichannels with internal diameters d = 0.31–3.30 mm. The results concern investigations of the local heat transfer coefficient and a pressure drop in single mini-channels. The results were compared with calculations according to the correlations proposed by other authors. Within the range of the examined parameters of the condensation process in mini-channels produced from stainless steel, it was established that the values of the heat transfer coefficient may be described with Akers et al. and Shah correlations within a limited range of the mass flux density of the refrigerant and the mini-channel diameter. A pressure drop during the condensation of these refrigerants is described in a satisfactory manner with Friedel and Garimella correlations. On the basis of the experimental investigations, the authors proposed their own correlation for the calculation of local heat transfer coefficient α_x.     

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.     

Experimental study of horizontal flattened tubes performance on condensation of R600a vapor

An empirical setup has been established to study heat transfer and pressure drop characteristics during condensation of R600a, a hydrocarbon refrigerant, in a horizontal plain tube and different flattened channels. Round copper tubes of 8.7 mm I.D. were deformed into flattened channels with different interior heights of 6.7 mm, 5.2 mm and 3.1 mm as test sections. The test conditions include heat flux of 17 kw/m², mass velocity in the range of 154.8–265.4 kg/m²s and vapor quality variation from approximately 10% to 80%. Results indicate that flattening the tubes causes significant enhancement of heat transfer coefficient which is also accompanied by simultaneous augmentation in flow pressure drop. Therefore, the overall performance of the flattened tubes with respect to heat transfer enhancement considering the pressure drop penalty is analyzed. It is concluded that the flattened tube with 5.2 mm inner height tube has the best overall performance. Due to the failure of pre-existing correlations for round tube condensation heat transfer, a new correlation is proposed which predicts 90% of the entire data within ± 17% error.     

Local heat transfer distribution and effect of instabilities during flow boiling in a silicon microchannel heat sink

Flow boiling of the perfluorinated dielectric fluid FC-77 in a silicon microchannel heat sink is investigated. The heat sink contains 60 parallel microchannels each of 100 μm width and 389 μm depth. Twenty-five evenly distributed temperature sensors in the substrate yield local heat transfer coefficients. The pressure drop across the channels is also measured. Experiments are conducted at five flow rates through the heat sink in the range of 20–80 ml/min with the inlet subcooling held at 26 K in all the tests. At each flow rate, the uniform heat input to the substrate is increased in steps so that the fluid experiences flow regimes from single-phase liquid flow to the occurrence of critical heat flux (CHF). In the upstream region of the channels, the flow develops from single-phase liquid flow at low heat fluxes to pulsating two-phase flow at high heat fluxes during flow instability that commences at a threshold heat flux in the range of 30.5–62.3 W/cm² depending on the flow rate. In the downstream region, progressive flow patterns from bubbly flow, slug flow, elongated bubbles or annular flow, alternating wispy-annular and churn flow, and wall dryout at highest heat fluxes are observed. As a result, the heat transfer coefficients in the downstream region experience substantial variations over the entire heat flux range, based on which five distinct boiling regimes are identified. In contrast, the heat transfer coefficient midway along the channels remains relatively constant over the heat flux range tested. Due to changes in flow patterns during flow instability, the heat transfer is enhanced both in the downstream region (prior to extended wall dryout) and in the upstream region. A previous study by the authors found no effect of instabilities during flow boiling in a heat sink with larger microchannels (each 300 μm wide and 389 μm deep); it appears therefore that the effect of instabilities on heat transfer is amplified in smaller-sized channels. While CHF increases with increasing flow rate, the pressure drop across the channels has only a minimal dependence on flow rate once boiling is initiated in the microchannels, and varies almost linearly with increasing heat flux.     

Effect of tube diameter on boiling heat transfer of R-134a in horizontal small-diameter tubes

The boiling heat transfer of refrigerant R-134a flow in horizontal small-diameter tubes with inner diameter of 0.51, 1.12, and 3.1 mm was experimentally investigated. Local heat transfer coefficient and pressure drop were measured for a heat flux ranging from 5 to 39 kW/m², mass flux from 150 to 450 kg/m² s, evaporating temperature from 278.15 to 288.15 K, and inlet vapor quality from 0 to 0.2. Flow patterns were observed by using a high-speed video camera through a sight glass at the entrance of an evaporator. Results showed that with decreasing tube diameter, the local heat transfer coefficient starts decreasing at lower vapor quality. Although the effect of mass flux on the local heat transfer coefficient decreased with decreasing tube diameter, the effect of heat flux was strong in all three tubes. The measured pressure drop for the 3.1-mm-ID tube agreed well with that predicted by the Lockhart–Martinelli correlation, but when the inner tube diameter was 0.51 mm, the measured pressure drop agreed well with that predicted by the homogenous pressure drop model. With decreasing tube diameter, the flow inside a tube approached homogeneous flow. The contribution of forced convective evaporation to the boiling heat transfer decreases with decreasing the inner tube diameter.     

Microchannel size effects on local flow boiling heat transfer to a dielectric fluid

Heat transfer with liquid–vapor phase change in microchannels can support very high heat fluxes for use in applications such as the thermal management of high-performance electronics. However, the effects of channel cross-sectional dimensions on the two-phase heat transfer coefficient and pressure drop have not been investigated extensively. In the present work, experiments are conducted to investigate the local flow boiling heat transfer of a dielectric fluid, Fluorinert FC-77, in microchannel heat sinks. Experiments are performed for mass fluxes ranging from 250 to 1600 kg/m² s. Seven different test pieces made from silicon and consisting of parallel microchannels with nominal widths ranging from 100 to 5850 μm, all with a nominal depth of 400 μm, are considered. An array of temperature sensors on the substrate allows for resolution of local temperatures and heat transfer coefficients. The results of this study show that for microchannels of width 400 μm and greater, the heat transfer coefficients corresponding to a fixed wall heat flux as well as the boiling curves are independent of channel size. Also, heat transfer coefficients and boiling curves are independent of mass flux in the nucleate boiling region for a fixed channel size, but are affected by mass flux as convective boiling dominates. A strong dependence of pressure drop on both channel size and mass flux is observed. The experimental results are compared to predictions from a number of existing correlations for both pool boiling and flow boiling heat transfer.     

An experimental study on the heat transfer performance and pressure drop of TiO2-water nanofluids flowing under a turbulent flow regime

Nanofluid is a new class of heat transfer fluids engineered by dispersing metallic or non-metallic nanoparticles with a typical size of less than 100 nm in the conventional heat transfer fluids. Their use remarkably augments the heat transfer potential of the base liquids. This article presents the heat transfer coefficient and friction factor of the TiO₂-water nanofluids flowing in a horizontal double tube counter-flow heat exchanger under turbulent flow conditions, experimentally. TiO₂ nanoparticles with diameters of 21 nm dispersed in water with volume concentrations of 0.2–2 vol.% are used as the test fluid. The results show that the heat transfer coefficient of nanofluid is higher than that of the base liquid and increased with increasing the Reynolds number and particle concentrations. The heat transfer coefficient of nanofluids was approximately 26% greater than that of pure vol.%, and the results also show that the heat transfer coefficient of the nanofluids at a volume concentration of 2.0 vol.% was approximately 14% lower than that of base fluids for given conditions. For the pressure drop, the results show that the pressure drop of nanofluids was slightly higher than the base fluid and increases with increasing the volume concentrations. Finally, the new correlations were proposed for predicting the Nusselt number and friction factor of the nanofluids, especially.     

Experimental investigation of condensation heat transfer and pressure drop of R22, R410A and R407C in mini-tubes

Condensation heat transfer and pressure drop of R22, R410A and R407C were investigated experimentally in two single round stainless steel tubes with inner diameter of 1.088 mm and 1.289 mm. Condensation heat transfer coefficients and two phase pressure drop were measured at the saturation temperatures of 30 °C and 40 °C. The mass flux varies from 300 to 600 kg/m² s and the vapor quality 0.1–0.9. The effects of mass flux and vapor quality were investigated and the results indicate that condensation heat transfer coefficients increase with mass flux and vapor quality, increasing faster in the high vapor quality region. The experimental data was compared with the correlations based on experimental data from large diameter tubes (d_h > 3 mm), such as the Shah and Akers correlations et al. Almost all the correlations overestimated the present experimental data, but Wang correlation and Yan and Lin correlation which were developed based on the experimental data from mini-tubes predicted present data reasonably well. Condensation heat transfer coefficients and two phase pressure drop of R22 and R407C are equivalent but both higher than those of R410A. As a substitute for R22, R410A has more advantages than R407C in view of the characteristics of condensation heat transfer and pressure drop.     

The importance of turbulence during condensation in a horizontal circular minichannel

Three-dimensional simulations of condensation of refrigerant R134a in a horizontal minichannel are presented. Mass fluxes ranging from 50 kg m^?2 s^?1 up to 1000 kg m^?2 s^?1 are considered in a circular minichannel of 1 mm diameter, and uniform wall and vapour–liquid interface temperatures are imposed as boundary conditions. The Volume of Fluid (VOF) method is used to track the vapour–liquid interface; the effects of interfacial shear stress, gravity and surface tension are taken into account. The influence of turbulence in the condensate film is analysed and compared against the assumption of laminar condensate flow by employing different computational approaches and validating the results against experimental data. Under the assumption of laminar condensate flow, experimental heat transfer coefficient values at low mass fluxes can be predicted, but the computed heat transfer coefficient is found to be almost independent of mass flux and vapour quality. Only when turbulence in the condensate film is taken into account does the numerical model capture the influence of mass flux that is observed in the experimental measurements.     

Correlation of critical heat flux and two-phase friction factor for subcooled convective boiling in structured surface microchannels

Critical heat flux (CHF) and pressure drop of subcooled flow boiling are measured for a microchannel heat sink containing 75 parallel 100 μm × 200 μm structured surface channels. The heated surface is made of a Cu metal sheet with/without 2 μm thickness diamond film. Tests and measurements are conducted with de-ionized water, de-ionized water +1 vol.% MCNT additive solution, and FC-72 fluids over a mass velocity range of 820–1600 kg/m² s, with inlet temperatures of 15(8.6)°C, 25(13.6)°C, 44(24.6)°C, and 64(36.6)°C for DI water (FC-72), and heat fluxes up to 600 W/cm². The CHF of subcooled flow boiling of the test fluids in the microchannels is measured parametrically. The two-phase pressure drop is also measured. Both CHF and the two-phase friction factor correlation for one-side heating with two other side-structured surface microchannels are proposed and developed in terms of the relevant parameters.     

Experimental study on condensation and evaporation flow inside horizontal three dimensional enhanced tubes

Experimental investigations of tube side condensation and evaporation in two 3-D enhanced heat transfer (2EHT) tubes were compared to the performance of a smooth surface copper tube. The equivalent outer diameter of all the tubes was 12.7 mm with an inner diameter of 11.5 mm. Both the inner and outer surfaces of the 2EHT tubes are enhanced by longitudinal grooves with a background pattern made up by an array of dimples/embossments. Experimental runs were performed using R410A as the working fluid, over the quality range of 0.2–0.9. For evaporation, the heat transfer coefficient ratio (compares the heat transfer coefficient of the enhanced tube to that of a smooth tube) of the 2EHT tubes is 1.11–1.43 (with an enhanced surface area ratio of 1.03) for mass flux rate that ranges from 80 to 200 kg/m² s. For condensation, the heat transfer coefficient ratio range is 1.1–1.16 (with an enhanced surface area ratio of 1.03) for mass flux that ranges from 80 to 260 kg/m² s. Frictional pressure drop values for the 2EHT tubes are very similar to each other. Heat transfer enhancement in the 2EHT tubes is mainly due to the dimples and grooves in the inner surface that create an increased surface area and interfacial turbulence; producing higher heat flux from wall to working fluid, flow separation, and secondary flows. A comparison was performed to evaluate the enhancement effect of the 2EHT tubes using a defined performance factor and this indicates that the 2EHT tubes provides a better heat transfer coefficient under evaporation conditions.