Flow Boiling Research Articles

3D Numerical Investigation of Bubble Upflow Condensation Behaviors During Subcooled Flow Boiling in Mini-Channel with VOSET

In the subcooled flow boiling process, bubble condensation is an inevitable basic phenomenon. This paper studies the condensation phenomenon of the single, double vertical/horizontal saturated bubbles rising in a three-dimensional mini-rectangular channel based on the interface capture method VOSET (coupled volume-of-fluid and level set method) and the phase transition model. Bubble condensation behaviors are investigated at different initial diameters, inlet velocity distributions, subcooling temperatures, bubble gaps, and arrangement for the two-bubble condensing system especially. The effects of these parametric on bubble motion trajectory, shape evolution, volume variation, and condensation rate are presented. The numerical results indicated that the initial bubble size and liquid subcooling play an important role in influencing the shape and volume variation of condensing bubble behaviors significantly, while the inlet velocity distribution only affects bubble motion trajectory. Furthermore, the interaction and coalescence between the bubbles will affect the bubble behaviors and the condensation rate. Finally, the condensation heat transfer coefficients at the bubble surfaces for different cases simulated in this paper are presented, seemingly first in the literature.

Effect of Forced Convection Heat Transfer on Vapor Quality in Subcooled Flow Boiling

Abstract A new theoretical model based on energy balance and well-known heat transfer correlations is proposed for predicting vapor quality in subcooled flow boiling. This model takes into account the enhancement of forced convection heat transfer due to the presence of vapor. It is shown that the vapor quality predicted by our model is much less than that by a previous model for low pressure. This result demonstrates that the convective heat transfer coefficient cannot be constant, and the effect of gas phase on forced convection heat transfer cannot be neglected even for subcooled flow boiling, particularly at low pressures. However, the difference between the present and previous models decreases as the pressure increases, because (i) the increase of the convective heat transfer coefficient is weakened, and (ii) boiling heat transfer becomes dominant. Furthermore, the present model has the capability of locating the point at which bulk boiling commences.

Investigation of Wall Boiling Closure, Momentum Closure and Population Balance Models for Refrigerant Gas–Liquid Subcooled Boiling Flow in a Vertical Pipe Using a Two-Fluid Eulerian CFD Model

The precise design of heat exchangers in automobile air conditioning systems for more sustainable electric vehicles requires an enhanced assessment of CFD mechanistic models for the subcooled boiling flow of pure eco-friendly refrigerant. Computational Multiphase Flow Dynamics (CMFDs) relies on two-phase closure models to accurately depict the complex physical phenomena involved in flow boiling. This paper thoroughly examines two-phase CMFD flow boiling, incorporating sensitivity analyses of critical parameters such as boiling closures, momentum closures, and population balance models. Three datasets from the DEBORA experiment, involving vertical pipes with subcooled boiling flow of refrigerant at three different pressures and varying levels of inlet liquid subcooling, are used for comparison with CFD simulations. This study integrates nucleate site density and bubble departure diameter models to enhance wall boiling model accuracy. It aims to investigate various interfacial forces and examines the S-Gamma and Adaptive Multiple Size-Group (A-MuSiG) size distribution methods for their roles in bubble break up and coalescence. These proposed approaches demonstrate their efficacy, contributing to a deeper understanding of flow boiling phenomena and the development of more accurate models. This investigation offers valuable insights into selecting the most appropriate sub-closure models for both boiling closure and momentum closure in simulating boiling flows.

Heat Transfer Estimation in Flow Boiling of R134a within Microfin Tubes: Development of Explainable Machine Learning-Based Pipelines

Heat Transfer Estimation in Flow Boiling of R134a within Microfin Tubes: Development of Explainable Machine Learning-Based Pipelines

Numerical Study on Subcooled Boiling Flow and Heat Transfer Characteristics in Helical Cruciform Fuel Assembly

The helical cruciform fuel rod is a new fuel design. Its advantages include a large surface area–to-volume ratio, short thermal conductivity distance, and no need for grid spacers. This new fuel rod can effectively improve the hydraulic performance of nuclear reactors. To study the performance of the helical cruciform fuel assembly, the subcooled boiling flow and heat transfer characteristics of this assembly are analyzed in the present work based on computational fluid dynamics. The results indicate that the temperature distribution of the central rod wall surface in the circumferential direction has inhomogeneity and periodicity. The fluid’s temperature and velocity distribution in the cross section are high in the center and low elsewhere, and the fuel rod’s torsional orientation is compatible with the velocity vector’s direction. The vapor volume fraction on the wall of the center rod of the fuel assembly is the highest, and the vapor volume fraction in the mainstream area is relatively low. This work provides a reference for further research on helical cruciform fuel assemblies in the thermal analysis of nuclear reactors.

CFD elucidation of high-pressure subcooled boiling flow towards effects of variable refrigerant properties using OpenFOAM empirical closures

Boiling flow presents a significant concern, especially when a liquid surpasses its boiling point, potentially leading to catastrophic consequences. This research utilizes a two-phase code in the OpenFOAM software to investigate bubble formation during flow boiling. The well-established empirical models for calculating wall heat components were selected based on the operating conditions. The study incorporates experimental data from high-pressure boiling flow (10–30 bars) with variable properties of refrigerant R-12. The predictions reveal underpredictions in void fraction and liquid temperature compared to experimental observations. Significantly, the impact of the subcooling degree on void fraction behaviour is emphasized, and a potential underprediction of the evaporation portion is highlighted, particularly near the wall. Challenges in modelling bubble size distribution are evident through discrepancies in bubble diameter and velocity data, indicating the necessity for further advancements in the code. In summary, this numerical study provides valuable insights into the intricate dynamics of high-pressure subcooled boiling flow, especially when considering variable working fluid properties. Future efforts will focus on refining models for nucleation site density, bubble departure size, and lift-off frequency to enhance prediction accuracy.

Computer-Vision- and Deep-Learning-Based Determination of Flow Regimes, Void Fraction, and Resistance Sensor Data in Microchannel Flow Boiling.

The aim of this article is to introduce a novel approach to identifying flow regimes and void fractions in microchannel flow boiling, which is based on binary image segmentation using digital image processing and deep learning. The proposed image processing pipeline uses adaptive thresholding, blurring, gamma correction, contour detection, and histogram comparison to separate vapor from liquid areas, while the deep learning method uses a customized version of a convolutional neural network (CNN) called U-net to extract meaningful features from video frames. Both approaches enabled the automatic detection of flow boiling conditions, such as bubbly, slug, and annular flow, as well as automatic void fraction calculation. Especially CNN demonstrated its ability to deliver fast and dependable results, presenting an appealing substitute to manual feature extraction. The U-net-based CNN was able to segment flow boiling images with a Dice score of 99.1% and classify the above flow regimes with an overall classification accuracy of 91%. In addition, the neural network was able to predict resistance sensor readings from image data and assign them to a flow state with a mean squared error (MSE) < 10-6.

Weakening of Ledinegg Instability and Maldistribution of Boiling Flow in Parallel Microchannels by Entry Effects

Weakening of Ledinegg Instability and Maldistribution of Boiling Flow in Parallel Microchannels by Entry Effects

Numerical Investigation of Flow Boiling in Interconnected Microchannels at Varying Mass Fluxes

Numerical Investigation of Flow Boiling in Interconnected Microchannels at Varying Mass Fluxes

Experimental and Computational Investigation of Flow Boiling in a 52 μm Hydraulic Diameter Microchannel Evaporator With Inlet Restrictions and Heat Spreading

Abstract Microchannel flow boiling presents an effective thermal management strategy for high heat flux (&amp;gt;1 kW/cm2) devices. Fundamental mechanisms of microchannel flow boiling behaviors are difficult to determine due to macroscopic limitations of experimental hardware. In addition, flow stabilizing features of microchannel evaporators such as inlet restrictions and heat spreading further complicate fluid flow and heat transfer dynamics. Computational models, when utilized with experiments, can provide a more detailed understanding of behaviors which cannot be determined experimentally. The present study developed a computational model for flow boiling heat transfer in a 52 μm silicon microchannel evaporator designed to cool a laser diode bar, with inlet restrictions and a nonuniform heating profile at the channel level. A conjugate heat transfer model along with a coupled level set and volume of fluid (CLSVOF) model was created in ansysfluent and compared with experimental flow boiling data to gain further insights into the performance of a realistic microdevice. Heat spreading in the channel outside of the heater footprint was observed due to the high thermal conductivity of the silicon substrate. The inlet orifices impacted local flow patterns by creating a large pressure drop and forming a recirculation zone immediately downstream. This behavior resulted in pressure recovery zones and regions of separated flow boiling behavior. Bubbly, slug, and churn flows were seen to be dominant flow regimes. The heat transfer coefficient was found to be dependent on heat flux and flow regime, and more weakly on mass flux and outlet vapor quality.

Thermal Characterization of Subcooled Flow Boiling in a Pin-Fin Coldplate With Non-Uniform Heating

Abstract Coldplates are a crucial component in various cooling applications, such as cooling data center servers and power electronics. The unprecedented growth in electronics power density, along with the resulting ultrahigh heat fluxes, demands a transition from single-phase forced convection to two-phase flow boiling heat transfer. The majority of studies in the literature have focused on flow boiling in fin-enhanced silicon microgaps and microchannels, with only a few addressing flow boiling in millimeter-scale heat sinks. In the present study, flow boiling of HFE-7200 dielectric fluid in a millimeter-scale pin-fin coldplate is experimentally investigated under nonuniform heating conditions. Four background heaters represent the low-dissipating-power devices. On the other hand, five hotspot heaters mimic the high-heat-flux devices and generate heat fluxes ranging from 50 W/cm2 to 1000 W/cm2, corresponding to hotspot heat inputs ranging from 62.5 W to 1.25 kW, respectively. The coldplate's thermohydraulic performance is investigated for various flow rates and inlet temperature ranging from 0.5 L/min to 1.5 L/min and from 25 °C to 60 °C, respectively. A high-speed camera is utilized for a narrow field of view (FOV) flow visualization at a frame rate of 2229 fps while a digital camera is used for a wider FOV at 60 fps. Flow visualization demonstrated the transition between bubbly, slug/churn, and stratified two-phase flow regimes.

Stability Criterion of a Rotating Fluid Film in the Post-Dryout Region of Swirling Flow Boiling

Stability Criterion of a Rotating Fluid Film in the Post-Dryout Region of Swirling Flow Boiling

Investigations of Flow Boiling in Mini-Channels: Heat Transfer Calculations with Temperature Uncertainty Analyses

The article aims to explore boiling heat transfer in mini-channels with a rectangular cross-section using various fluids (HFE-649, HFE-7000, HFE-7100, and HFE-7200). Temperature measurements were conducted using infrared thermography for the heated wall and K-type thermocouples for the working fluid. The 2D mathematical model for heat transfer in the test section was proposed. Local heat transfer coefficients between the heated wall and the working fluid were determined from the Robin condition. The problem was solved by means of the finite element method (FEM) with Trefftz functions. The values of the heat transfer coefficient that were obtained were compared with the results calculated from Newton’s law of cooling. The average relative differences between the obtained results did not exceed 4%. The study included uncertainty analyses for temperature measurements with K- and T-type thermocouples. Expanded uncertainties were calculated using the uncertainty propagation and Monte Carlo methods. Precisely determining the uncertainties in contact temperature measurements is crucial to ensure accurate temperature data for subsequent heat transfer calculations. The results of the heat transfer investigations were compared in terms of fluid temperature, heat transfer coefficients, and boiling curves. HFE-7200 consistently exhibited the highest fluid temperature and temperature differences at boiling incipience, while HFE-7000 demonstrated the highest heat transfer coefficients. HFE-649 showed the lowest heat transfer coefficients. The boiling curves exhibited a typical shape, with a notable occurrence of ‘nucleation hysteresis phenomena’. Upon the analysis of two-phase flow patterns, bubbly and bubbly-slug structures were observed.

Water Flow Boiling in Micro/Mini Channels Using Volume of Fluid Model

Recent advancements in computational fluid dynamics (CFD) have triggered research in the field of heat exchangers. Driven by the need to decrease the size of heat exchangers, many researchers have exploited the higher heat transfer achieved by replacing single-phase flow systems with boiling counterparts. The concept of using mini-channels to provide compact heat exchangers while maintaining heat transfer performance is relatively new. A minimal number of researchers have reported simulations of water-steam systems in mini-channels. This paper presents a numerical study of the heat transfer performance (HTP) of mini channels in a water-steam system using the volume of fluid (VOF) model coupled with the Lee phase change model on commercial CFD software ANSYS. The numerical model consisted of a 1 mm × 1.5 mm × 52 mm channel with boundary conditions: top adiabatic; constant heat flux at the bottom surface; left/right periodic; mass flow inlet and pressure outlet. A mesh independence study was carried out for the proposed model, and simulations were validated against the experimental results of heat transfer versus vapor quality for a wide range of mass and heat fluxes. The VOF model best predicts experimental HTC at high mass fluxes, although the results at low mass fluxes were predicted with reasonable accuracy. Based on the agreement of numerical and numerical results, the VOF model turned out to be a promising candidate for designing compact micro/mini channel heat exchangers.

Influence of Microfin Tube on Heat Transfer during Flow Boiling of R134a Refrigerant

This research looks into the domination of flow boiling on the efficiency and sustainability of refrigeration and air conditioning systems. Specifically, it focuses on the characteristics related with heat transfer of refrigerant R134a within both smooth and microfin tubes, each having 9.52 mm outer diameter. The features of microfin tube have distinct configuration with a 46° apex angle and a 22° helix angle, resulting in a surface area 1.62 times greater in comparison to smooth tube. Through a comprehensive experimental analysis, the study examines the influence of key parameters (mass flux; saturation temperature; heat flux; and average vapor quality) on heat transfer coefficients (HTCs). Notably, the HTC exhibits significant enhancements at mass flux of G = 125 kg m⁻2·s⁻1, encountering challenges related to dry‐out at elevated vapor quality levels. The results reveal that microfin tubes consistently outperform smooth tubes, exhibiting heat transfer coefficients up to 270% higher across various operational conditions. Furthermore, the experimental data are rigorously validated through computation analysis with authentic flow boiling heat transfer models, demonstrating strong agreement.

FLOW BOILING HEAT TRANSFER IN MICROCHANNEL HEAT EXCHANGERS WITH MICRO POROUS COATING SURFACE

This study experimentally investigated the heat transfer and pressure drop performance of refrigerant HFC-245fa flow boiling in microchannel heat exchangers with and without microporous coating. The flow boiling heat transfer performance at various mass fluxes, heating rate, exit vapor qualities, and surface coating thickness was compared. The test results showed that the 52 &amp;mu;m coating thickness porous surface exhibited 65-148&amp;#37; higher heat transfer performance than the smooth surface, while the 98 &amp;mu;m microporous coating surface showed a lower improvement of 41-90&amp;#37; at various mass fluxes. Partial dry out was observed at high and moderate mass fluxes on both smooth and porous coating channels. It happened at lower exit vapor qualities in microporous coating channels than that in smooth channels. The partial dry-out exit vapor qualities increased with decreasing mass fluxes. For the lowest mass flux, because of the low heat flux and low nucleation suppression, no significant partial dry out was investigated. The pressure drops in microporous coating channels were around 25-47&amp;#37; higher than those in smooth channels. There was no significant influence of microporous coating layer thickness on flow boiling pressures drops.

Effect of Channel Aspect Ratio on Flow Boiling in Mini-Channels

Effect of Channel Aspect Ratio on Flow Boiling in Mini-Channels

FLOW BOILING HEAT TRANSFER COEFFICIENT USED FOR THE DESIGN OF THE EVAPORATOR OF A REFRIGERATION MACHINE USING CO2 AS WORKING FLUID

In this work, a comparative study of the heat transfer coefficient of carbon dioxide (CO&lt;sub&gt;2&lt;/sub&gt;) in evaporation is presented. The main objective of the this work is to analyze and evaluate 1886 experimental points of the CO&lt;sub&gt;2&lt;/sub&gt; heat transfer coefficient with the help of two evaporation correlations (Fang et al., 2013, 2017); the correlation of Fang et al. (2017) gives the best results with a mean absolute deviation of 6.04&amp;#37;.

A Review on Flow Boiling of the Fluid with Lower Boiling Point in Micro-Channels

A Review on Flow Boiling of the Fluid with Lower Boiling Point in Micro-Channels

Design and optimization of molten salt printed circuit steam generators

Among the array of heat exchangers available, printed circuit steam generators emerge as a particularly promising choice for high-temperature applications. This is primarily attributed to their augmented heat transfer surface area, which enables the efficient transfer of thermal energy within the Rankine power conversion cycle, especially in the context of molten salt-based thermal power systems, such as those employed in molten salt reactors and concentrated solar power plants. It is imperative to analytically model the heat transfer characteristics of mini-channel flow boilings for a printed circuit steam generator. To resolve new technical design issues that the single hot fluid flow channel is cooled by multiple cold fluid flow channels, an improved heat exchanger model is proposed to assist the numerical modeling of printed circuit steam generators for molten salt based on the equilibrium thermodynamics quality of water/steam flow. The existing flow boiling heat transfer coefficient correlations of mini-channels are leveraged to optimally design the straight-passage based printed circuit layouts and narrow down their optimal operational parameters. With various selections of subcooled water, saturated water, and superheated steam heat transfer correlations, The best combination of heat transfer correlations is found to assess the axial distributions of cold fluid temperatures and pressure drops. Two multi-objective optimizations are formulated to respectively solve thermal sizing and scaling problems for the optimal designs and operations of printed circuit steam generators. The computational results indicate that the overall heat transfer coefficient for an optimized 50 MW(th) printed circuit steam generator assessed at the transition point is about 3,828 W/(m2 K), which remarkably surpasses the 1,544 W/(m2 K) value of the conventional shell-tube steam generators by a factor of three. This implies that printed circuit steam generators would be a promising replacement of the traditional shell-tube steam generator.