Experimental investigation of in-line tube bundle heat transfer process to vertical downward foam flow

Usage of two phase flow as a coolant allows to reach more intensive heat transfer process. This paper presents the results of the investigation of the heat transfer between the in-line tube bundle and statically stable aqueous foam flow. The flow of the foam was generated at the top of the experimental channel and crossed down the tubes of the bundle (the diameter of the tubes was 0.02 m; horizontal and vertical distances between the centers of the tubes – 0.03 m). This investigation allowed determining the dependence of the heat transfer intensity of the tubes to foam flow on the volumetric flow rate and volumetric void fraction of the foam. The influence of tube position in the bundle on the intensity of heat transfer was found in this experimental study: the intensity of the heat transfer between the middle tube and the downward foam flow was determined to be higher comparing to the intensity between the tubes in both sideways of the bundle and the downward foam flow. The results of investigation showed that an average heat transfer intensity of the tubes of in-line bundle to downward without any turning foam flow was higher than that in the case of the downward after 180° turning foam flow. The results of this experimental study were generalized using the empirical equation between heat transfer coefficient from one side and the volumetric flow rate and volumetric void fraction of the foam from the other side.     

Investigation of flow phenomena in a kettle reboiler

Two-phase flow phenomena were investigated while boiling R113 and n-pentane in a 241-tube thin slice kettle reboiler. For heat fluxes between 10 and 40 kW/m², row pressure drop measurements were made in three columns and visual observations of the flow patterns were recorded by a video camera. The height of the two-phase mixture above the tube bundle was also varied. The results revealed that the height of the mixture had little effect on the row pressure drop distribution in each column. At heat fluxes below 10 kW/m², the pressure drops were reasonably constant. However, at heat fluxes greater than this, the row pressure drop continuously declined.Two one-point-five-dimensional models were developed, one to aid the investigation of static liquid driven lateral flow in the tube bundle, and another to aid the investigation of the cause of the change from reasonably constant to continually declining row pressure drop. The data and the analysis showed that the flow within the tube bundle was always two-dimensional and that the flow pattern was dominated by the static liquid at the tube bundle edge when the heat flux was less than 10 kW/m². This corresponded to the bubbly flow regime. At larger heat fluxes, the flow pattern changed to intermittent flow. The change occurred when the Kutateladze number was 1.09. Declining row pressure drops occurred in this latter flow regime.     

Entropy generation of vapor condensation in the presence of a non-condensable gas in a shell and tube condenser

This article investigates the entropy production of condensation of a vapor in the presence of a non-condensable gas in a counter-current baffled shell and one-pass tube condenser. The non-dimensional entropy number is derived with respect to heat exchange between the bulk fluid and condensate, as well as heat exchange between the condensate and coolant. Numerical results show that heat transfer from the condensate to the coolant has a dominant role in generating entropy. For example, at an air mass flow rate of 330 kg/h, 93.4% of the total entropy generation is due to this source. The resultant profiles during the condensation process indicate that a higher air mass flow rate leads to a lower rate of entropy production. For example, as the air mass flow rate increases from 330 kg/h to 660 kg/h and 990 kg/h, the total entropy generation decreases from 976 J/s K to 904 and 857.2 J/s K, respectively. By introducing a new parameter called the condensation effectiveness, a correlation is also developed for predictions of the entropy number, and an illustrative example is presented.     

Boiling two-phase flow and efficiency of co- and counter-current microchannel heat exchangers with gas heating

To learn how to utilize the exhaust heat from a high-temperature gas product of a methanol reformer, the present study experimentally investigates the boiling two-phase flow in co- and counter-current microchannel heat exchangers (MCHE) with gas heating. Boiling two-phase flow patterns, two-phase flow instability, and efficiency are explored. The working fluid on the hot and cold sides are helium and liquid methanol, respectively. The silicon-based MCHE, which has dimensions of 20 mm × 20 mm, is designed with 18 parallel microchannels on both sides and is prepared using microfabrication processes. Four types of two-phase flow patterns – bubbly-elongated slug flow, annular flow, annular flow with liquid film breakup, and dryout are identified in both types of MCHE that are studied. A flow pattern map is then constructed on the plane of the methanol mass flux versus heat flux for both types of MCHE. In the counter-current MCHE, the efficiency increases significantly with an increase in the mass flux in both the single- and two-phase flow regions, while the effect of mass flux is insignificant in the co-current MCHE. In the two-phase flow region, the efficiency of both types of MCHEs gradually increases with an increase in the hot-side thermal power until the CHF is approached. The highest efficiency obtained in the present study is about 0.85 and 0.90 for the co- and counter-current MCHEs, respectively.     

Experimental study of evaporation heat transfer of R-134a inside a corrugated tube with different tube inclinations

Experimental heat transfer studies during evaporation of R-134a inside a corrugated tube have been carried out. The corrugated tube has been provided with different tube inclination angles of the direction of fluid flow from horizontal, α. The experiments were performed for seven different tube inclinations, α, in a range of − 90° to + 90° and four mass velocities of 46, 81, 110 and 136 kg m^− 2 s^− 1 for each tube inclination angle during evaporation of R-134a. Data analysis demonstrate that the tube inclination angle, α, affects the boiling heat transfer coefficient in a significant manner. The effect of tube inclination angle, α, on heat transfer coefficient, h, is more prominent at low vapor quality and mass velocity. In the low vapor quality region, the heat transfer coefficient, h, for the + 90° inclined tube is about 62% more than that of the − 90° inclined tube. The results also showed that at all mass velocities, the highest average heat transfer coefficient were achieved for α = + 90°. An empirical correlation has also been developed to predict the heat transfer coefficient during flow boiling inside a corrugated tube with different tube inclinations.     

An asymptotic approach to generalizing the experimental data on convective heat transfer of tube bundles in crossflow

Based on the analysis of experimental data the universal methods of calculating convective heat transfer of smooth and finned tube bundles in the crossflow have been developed over the ranges of geometric characteristics covering all practical needs at the Reynolds number Re = 3 × 10³…1 × 10⁵.The distinctive feature of the methods proposed is that the generalized similarity equation of convective heat transfer takes into account the dependence of the Reynolds number exponent on tube pitch characteristics in a bundle. This has allowed the mechanism of heat transfer and hydraulic performance in tube bundles to be taken into utmost consideration and the asymptotic character to be given to the generalized dependence. In turn, this has permitted one to show the presence of maximum of heat transfer intensity and also to cover limiting combinations of pitches, at which differences in staggered and in-line arrangements of tubes are leveled, i.e., practically the restrictions on the ranges of tube pitch characteristics of bundles can be removed.     

Optimization of the angle of attack of delta-winglet vortex generators in a plate-fin-and-tube heat exchanger

Delta-winglet vortex generators (VGs) are known to enhance the heat transfer between the energy-carrying fluid and the heat transfer surfaces in plate-fin-and-tube banks. In this study optimal angles of attack of the delta-winglets are investigated based on the Pareto optimal strategy. The optimization process combines a CFD analysis, genetic algorithms and the response surface methodology. The angle of attack of a pair a delta-winglet-type VGs mounted behind each tube is varied between β = ?90° and +90°. Three circular tube rows with inline and staggered tube arrangements are investigated for Reynolds numbers from 200 to 1200 (based on the inlet height and inlet velocity). The flow structure and heat transfer behavior is analyzed in detail for certain cases and the staggered and the inline tube arrangements are compared. Finally, for each of these arrangements the optimal sets of angles of attack for different Reynolds numbers are presented.     

Cooling of microprocessors using flow boiling of CO2 in a micro-evaporator: Preliminary analysis and performance comparison

The flow pattern based flow boiling heat transfer and two-phase pressure drop models for CO₂, recently developed by Cheng et al. [L. Cheng, G. Ribatski, J. Moreno Quibén, J.R. Thome, New prediction methods for CO₂ evaporation inside tubes: Part I – A two-phase flow pattern map and a flow pattern based phenomenological model for two-phase flow frictional pressure drops, Int. J. Heat Mass transfer 51 (2008) 111–124; L. Cheng, G. Ribatski, J.R. Thome, New prediction methods for CO₂ evaporation inside tubes: Part II – An updated general flow boiling heat transfer model based on flow patterns, Int. J. Heat Mass transfer 51 (2008) 125–135], have been used to predict the thermal performance of CO₂ in a silicon multi-microchannel evaporator (67 parallel channels with a width of 0.223 mm, a height of 0.68 mm and a length of 20 mm) for cooling of a microprocessor. First, some simulation results of CO₂ flow boiling heat transfer and two-phase pressure drops in microscale channels are presented. The effects of channel diameter, mass flux, saturation temperature and heat flux on flow boiling heat transfer coefficients and two-phase pressure drops are next addressed. Then, simulations of the base temperatures of the silicon multi-microchannel evaporator using R236fa and CO₂ were performed for the following conditions: base heat fluxes from 20 to 100 W/cm², a mass flux of 987.6 kg/m²s and a saturation temperature of 25 °C. These show that the base temperatures using CO₂ are much lower than those using R236fa. Compared to R236fa, CO₂ has much higher heat transfer coefficients and lower pressure drops in the multi-microchannel evaporator. However, the operation pressure of CO₂ is much higher than that of R236fa. Based on the analysis and comparison, CO₂ appears to be a promising coolant for microprocessors at low operating temperatures but also presents a great technological challenge like other new cooling technologies.     

Single and two-phase flow modeling and analysis of a coaxial vacuum tube solar collector

In this paper, an analytical steady state model is developed to study the thermal performance of an individual vacuum tube solar collector with coaxial piping (direct flow type) incorporating both single and two-phase flows. A system of equations which describe the different heat transfer mechanisms and flow conditions was established, discretised, and solved in an iterative manner. For the case of good vacuum condition (10^?5 mb) the calculated efficiency curve for single phase flow deviates significantly from the experiments with increasing collector temperature, but agrees well for the case of gas conduction inside the glass envelope at very low pressure (?1 mb) due to the corresponding increase in overall heat loss coefficient (U-value).For two-phase flow, the occurrence and propagation of flow boiling and condensation inside the collector piping under saturated condition is hypothesized. The modeling results indicate that for all-liquid-single-phase fluid flow, the collector efficiency decreases with decreasing mass flow rate. Once the fluid reaches the boiling point at a certain mass flow rate, no significant reduction in efficiency is observed anymore, which is in accordance with the experimental study.     

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.     

The effect of pulsed electric fields on horizontal tube side convective condensation

The effect of pulsed electric fields on two-phase flow patterns, heat transfer and pressure drop in horizontal tube side convective condensation was investigated. Experiments were performed for an applied pulse voltage of 8 kV at pulse repetition rates in the range of 0.5 Hz–1.5 kHz and duty cycles of 25%, 50% and 75%. Three mass fluxes of 55, 100, and 150 kg/m² s were tested with an average vapour quality of 45% which corresponds to an initially stratified flow. The voltage was applied through a central electrode along the centerline of the tube. Changing the pulse repetition rate and duty cycle results in different flow patterns and therefore in different values of heat transfer and pressure drop. For a given mass flux, the heat transfer enhancement due to the applied voltage decreased with the pulse repetition rate and reached a plateau. The pressure drop ratio, however, increased with pulse repetition rate and reached a maximum before decreasing with a further increase in pulse repetition rate.     

Hydrodynamic cavitation and boiling in refrigerant (R-123) flow inside microchannels

This research article investigates the effect that hydrodynamic cavitation has on heat transfer. The fluid medium is refrigerant R-123 flowing through 227 μm hydraulic diameter microchannels. The cavitation is instigated by the inlet orifice. Adiabatic tests were conducted to study the two-phase cavitating flow morphologies and hydrodynamic characteristics of the flow. Diabatic experiments were performed resulting in surface temperatures under heat fluxes up to 213 W/cm² and mass velocities from 622 kg/m² s to 1368 kg/m² s. Results were compared to non-cavitating flows at the same mass velocities. It was found that the cavitating flows can significantly enhance the heat transfer. The heat transfer coefficient of the cavitating flows was larger than the non-cavitating flows by as much as 84%. Single-phase and two-phase heat transfer coefficients have been elucidated and employed to deduce the heat transfer mechanism prevailing under boiling conditions with and without the presence of cavitation.     

Flow boiling heat transfer coefficient of R-134a/R-290/R-600a mixture in smooth horizontal tubes using varied heat flux method

An experimental study on in-tube flow boiling heat transfer of R-134a/R-290/R-600a refrigerant mixture has been carried out under varied heat flux test conditions. The heat transfer coefficients are experimentally measured at temperatures between ?8 and 5 °C for mass flow rates of 3–5 g s^?1. Acetone is used as a hot fluid which flows in the outer tube of diameter 28.57 mm while the refrigerant mixture flows in the inner tube of diameters 9.52 and 12.7 mm. By regulating the acetone flow conditions, the heat flux is maintained between 2 and 8 kW/m² and the pressure of the refrigerant is maintained between 3.2 and 5 bar. The comparison of experimental results with the familiar correlations shows that the correlations over predict the heat transfer coefficients for this mixture when stratified and stratified-wavy flow prevail. Multiple regression technique is used to evolve and modify existing correlations to predict the heat transfer coefficient of the refrigerant mixture. It is found that the modified version of Lavin–Young correlation (1965) predicts the heat transfer coefficient of the considered mixture within an average deviation of ±20.5 %.     

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.     

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.     

Effect of surfactant addition on boiling heat transfer in a liquid film flowing in a diverging open channel

An experimental study was conducted to investigate how the addition of small amounts of a surfactant influences the heat transfer characteristics in a thin boiling liquid film flowing in a diverging open channel. Heat transfer experiments were conducted with fluid inlet temperatures from 40 °C to 92 °C. The flow field on the plate included thin film supercritical flow upstream of a hydraulic jump and thick film subcritical flow downstream of a hydraulic jump. Nusselt numbers for the non-boiling heat transfer without surfactant addition scaled linearly with the film Reynolds number. The boiling heat transfer produced higher Nusselt numbers with a weaker dependence on the Reynolds number. Experimental results showed that a boiling surfactant solution created a thick foam layer with high heat transfer rates and Nusselt numbers that are very weakly dependent on the inlet flow rate or the inlet Reynolds number.     

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.     

Experimental analysis of flow and heat transfer in a miniature porous heat sink for high heat flux application

A novel miniature porous heat sink system was presented for dissipating high heat fluxes of electronic device, and its operational principle and characteristics were analyzed. The flow and heat transfer of miniature porous heat sink was experimentally investigated at high heat fluxes. It was observed that the heat load of up to 280 W (heat flux of 140 W/cm²) was removed by the heat sink with the coolant pressure drop of about 34 kPa across the heat sink system and the heater junction temperature of 62.9 °C at the coolant flow rate of 6.2 cm³/s. Nu number of heat sink increased with the increase of Re number, and maximum value of 323 for Nu was achieved at highest Re of 518. The overall heat transfer coefficient of heat sink increased with the increase of coolant flow rate and heat load, and the maximal heat transfer coefficient was 36.8 kW(m² °C)^?1 in the experiment. The minimum value of 0.16 °C/W for the whole thermal resistance of heat sink was achieved at flow rate of 6.2 cm³/s, and increasing coolant flow rate and heat fluxes could lead to the decrease in thermal resistance. The micro heat sink has good performance for electronics cooling at high heat fluxes, and it can improve the reliability and lifetime of electronic device.     

Evaluation of the performance of the empirical correlations used to predict R134a's boiling frictional pressure drop inside smooth and corrugated tubes

Owing to the generalization problem, there aren't sufficient empirical correlations for two-phase flows. So as to investigate the thermal features of the two-phase flow in smooth and enhanced tubes, a suitable procedure of the models and correlations related with the heat transfer coefficients, friction factors and two-phase multipliers are needed because a significant variation in thermal properties happens during phase-change. Comparison of frictional pressure drop of R134a during flow boiling phenomena occurred in a smooth and 5 enhanced tubes with well-known empirical correlations were performed in this study. The apparatus has 0.85 m long double tube for vertical configuration as a test section that includes smooth and corrugated copper tubing having inner diameters of 0.0087 m, and the range of mass fluxes are between 200 and 400 kg m^− 2 s^− 1. The average vapor qualities vary from 0.14 to 0.86, and saturation pressure interval is between 4.5 and 5.7 bar. The mean boiling heat transfer coefficient of R134a is determined via energy balance in the test section. The estimation performance of 36 empirical correlations in literature proposed for convective boiling flows in smooth and corrugated tubes are evaluated by means of authors' database (350 data points for vertical tubes). Boiling trend lines have been plotted for the change of vapor quality, liquid phase Reynolds numbers with gas phase ones. In addition, the most successful correlations are confirmed their predictabilities for the vertical adjusted evaporator having smooth and corrugated tubes using the database of authors' earlier publications in open sources.     

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.