Small Diameter Channels Research Articles

Operation characteristics and limitations of small-diameter two-phase closed thermosyphon

Two-phase closed thermosyphon (TPCT) is a latent heat-based, high-efficiency heat transfer device primarily utilized in heat pipe heat exchangers in waste heat recovery (WHR) applications. Recently, there has been increasing interest in small-diameter TPCT due to thermal confinement issues and space and cost limitations of heat transfer devices. The nature of the two-phase flow and the resulting thermal performance of a small-diameter thermosyphon differ from that of a large-diameter thermosyphon, which is called the “confinement effect” of TPCT. In the present study, we experimentally explored the internal flow and heat transfer characteristics of TPCT with a very small inner diameter of 5 mm. Based on the Laplace length, which means the characteristic bubble size, four working fluids were considered: water, acetone, ethanol, and the HFE-7000. As a result, except for a specific condition where the degree of confinement and heat flux were very low, the shear force between the falling liquid condensate and upward vapor prevented the smooth circulation of working fluid inside the small-diameter channel. This caused local dry-out of the evaporator, resulting in the effective thermal conductivity of the TPCT being lower than that of the copper block.

A Navier-slip model for liquid film thickness in gas–liquid slug flow in capillaries

ABSTRACT The motion of a long gas bubble in a continuous liquid phase in a small diameter channel results in a thin liquid film between the bubble and the channel wall. Generally, a free-slip (zero shear) boundary condition is applied at the gas–liquid interphase boundary which is applicable only at low gas velocities. However, at increased flow rates of gas phase, shear stress at the gas–liquid interface is non-negligible. Applying non-zero shear at the interface requires knowledge of velocity profile in the gas phase. In this work, we circumvent this problem by using a slip length like parameter to take into account the velocity gradient in the gas phase. The slip length is infinite for the free-slip condition at the interface and zero for the no-slip condition. An expression is derived for the film thickness in terms of slip length and capillary number and is compared with the experimental data and other correlations available in the literature.

Bed structure of CNT agglomerates in gas–solid fluidized beds

In this study, the bed structure according to the flow regime of fine particles in gas–solid fluidized beds was studied by measuring the pressure drop and heat transfer coefficient. Two types of carbon nanotube (CNT) agglomerates with behavior similar to Geldart A and Geldart B and two types of glass bead (GB) particles corresponding to Geldart A and Geldart B classification were used. CNTs fluidized in the form of agglomerates, and in some CNT agglomerates, a homogeneous expansion regime with suppressed generation of bubbles, were observed. In the homogeneous expansion regime of CNT agglomerates, the relationship between superficial velocity and voidage was consistent with the Richardson–Zaki equation, and had a higher n value than that of Geldart A particles and fumed silica agglomerates. In this regime, small-diameter channels coexisted, and due to unstable fluidization at low superficial velocity, intermittent bed collapse occurred. In the homogeneous expansion regime of GB particles, the heat transfer coefficient remained constant, and as bubbles were generated, the heat transfer coefficient increased. On the other hand, as the superficial velocity increased, the heat transfer coefficient of CNT agglomerates continuously increased, regardless of the flow regime transition. In the homogeneous expansion regime of CNT agglomerates, unlike Geldart A particles, movement of agglomerates within the bed was confirmed, and a dynamic bed structure was present, in which the movement increased according to the superficial velocity.

Thermal and Visualisation Study of the HFE7100 Refrigerant Condensation Process

Abstract Technological advances are contributing to the search for highly efficient energy designs, and increasing interest in compact heat exchangers. Indeed, small channel diameters determine large heat transfer coefficients and condition a significant heat transfer area about the overall volume of the heat exchanger, as well as a smaller amount of refrigerant flowing in the system. Nevertheless, the operating stability and energy efficiency of compact heat exchangers are influenced by two-phase flow structures, which depend on thermal flow parameters. Knowledge of the structures formed during the condensation process is therefore essential for optimising the operation of refrigeration and air-conditioning equipment. This article presents the results from experimental studies of the HFE7100 refrigerant, from the hydrofluorocarbon group, condensation process in mini-channels with hydraulic diameters dh = 2.0 mm, 1.2 mm, 0.8 mm and 0.5 mm. Thermal flow characteristics were determined, and the forming structures of two-phase flow were recorded. The results of visualisation were subjected to morphological image analysis, based on a special algorithm written in MATLAB software. The algorithm makes it possible to determine the void fraction, which is necessary for calculating the vapour quality, as well as the area of vapour bubbles and their number, directionality and length along the x- and y-axes.

An experimental investigation on R245fa and R1233zd(E) flow boiling at high saturation temperatures in a horizontal small diameter channel

The current study presents an investigation on flow patterns, pressure-drop and heat transfer coefficient for the refrigerants R1233zd(E) and R245fa flowing at saturation temperatures (Tsat) between 75 °C and 95 °C inside a horizontal 2 mm diameter tube. Experimental results are reported for mass velocities of 176–570 kg/m²s and heat fluxes of 18.1–54.5 kW/m². As expected, the pressure gradient increases as the mass velocity increases and the saturation temperature decreases. Flow image analysis indicated that the pressure gradient peak is associated with disturbance interfacial waves damping. Heat transfer coefficient data indicated strong contribution of nucleate boiling effects for most of the experimental conditions. The higher the saturation temperature and the heat flux, the higher the heat transfer coefficient, regardless of the vapor quality range. In general, the effect of mass velocity on the heat transfer coefficient was only marginal, with exception of low Tsat and heat flux conditions. Two of 20 pressure-drop prediction methods predicted more than 90% of the database within error bands of ±30%. Overestimation of heat transfer coefficient data was verified for most of the 16 evaluated prediction methods, especially at high Tsat. Only two methods predicted more than 80% of data within an error band of ±30%.

Investigation on the effect of the cooler design on the performance of onboard supercritical carbon dioxide power cycle for hypersonic vehicles

The scramjet cooling and power generation are the key demands for the hypersonic vehicle. To satisfy the cooling and electricity generation requirements of hypersonic vehicles, the onboard supercritical carbon dioxide (sCO2) power cycle is adopted in this paper. Moreover, the cooler design has a significant effect on the feasibility and overall performance of onboard sCO2 power cycle, but there is no research considering the effect of the cooler design. Accordingly, the effects of the cooler design on the overall performance of onboard sCO2 power cycles applied in hypersonic vehicles are comprehensively investigated based on the thermodynamic models. The results indicated that the optimum cooler designs are suggested to adopt a small channel diameter and a relatively large channel number for minimizing the cooler mass and fuel consumption for cooling sCO2 and maximizing the system thermal efficiency. Moreover, the cold channel diameter is designed to be smaller than the hot channel diameter. The cold channel number is required to be larger than the hot channel number. The total flow area of cold channel is smaller than that of hot channel. The geometric parameters of cooler hot channel could be designed based on the Re ranging from 15,000 to 34,000.

What alternatives to computed tomography for inspection of additive manufacturing parts with channels

Non-destructive inspection of parts with small diameter channels is a major challenge. Additive Manufacturing (AM) offers many advantages compared to the traditional subtractive manufacturing process for the manufacturing of these complex structures. Thales, Safran and ArianeGroup joined forces to find a way to inspect parts with small diameter channels by technics other than X-ray computed tomography. LNE and Institut de Soudure (French welding institute) worked with them to identify, propose and test non-destructive techniques capable to detect flaws and cavities containing unfused powder unique to the powder-bed fusion AM process category. This paper will present some results of this project called FA- Canalsafe®. Artificial defects created on mock-ups will be described. Some results and limitations on eddy current testing and on visual endoscopy will be discussed. Finally, some recommendations on NDT implementation will be proposed.

Study the Performance of a Dynamic Wall Heat Exchanger Using Computational Fluid Dynamics

Thermal systems in small devices like cooling electronic chips require efficient technologies with small diameter channels. These systems have laminar flow and disrupted boundary layers, leading to high pressure drop values. To ensure sufficient flow and limit coolant temperature, a possible solution is to dynamically deform one channel wall to mimic pumping and disrupt boundary layers, creating a peristaltic effect, called a dynamic heat exchanger. The aim of the present numerical study is to explore the effects of different operating parameters of the dynamic wall heat exchanger on the heat transfer performance. In our numerical study we varied different operating parameters (amplitude of vibration A, frequency f, minimum gap between upper and lower wall H and pressure difference P) and observed how it affects the performance of the dynamic wall heat exchanger in terms of mass flow rate of coolant (water) and heat transfer coefficient. A crucial finding is that the distribution of isotherms and streamlines is adequate, and heat transfer is significant when the relative amplitude is high. Additionally, this type of wall can generate substantial heat transfer even with minimal externally applied pressure.

A miniaturized transit-time ultrasonic flowmeter based on ScAlN piezoelectric micromachined ultrasonic transducers for small-diameter applications

Transit-time ultrasonic flowmeters (TTUFs) are among the most widely used devices for flow measurements. However, traditional TTUFs are usually based on a bulk piezoelectric transducer, which limits their application in small-diameter channels. In this paper, we developed a miniaturized TTUF based on scandium-doped aluminum nitride (ScAlN) piezoelectric micromachined ultrasonic transducers (PMUTs). The proposed TTUF contains two PMUT-based transceivers and a π-type channel. The PMUTs contain 13 × 13 square cells with dimensions of 2.8 × 2.8 mm2. To compensate for the acoustic impedance mismatch with liquid, a layer of polyurethane is added to the surface of the PMUTs as a matching layer. The PMUT-based transceivers show good transmitting sensitivity (with 0.94 MPa/V surface pressure) and receiving sensitivity (1.79 mV/kPa) at a frequency of 1 MHz in water. Moreover, the dimensions of the π-type channel are optimized to achieve a measurement sensitivity of 82 ns/(m/s) and a signal-to-noise ratio (SNR) better than 15 dB. Finally, we integrate the fabricated PMUTs into the TDC-GP30 platform. The experimental results show that the developed TTUF provides a wide range of flow measurements from 2 to 300 L/h in a channel of 4 mm diameter, which is smaller than most reported channels. The accuracy and repeatability of the TTUF are within 0.2% and 1%, respectively. The proposed TTUF shows great application potential in industrial applications such as medical and chemical applications.

Desulfurization of oxidized diesel fuel in a spiral micro-channel contactor under ultrasound irradiation

The extractive desulfurization of the oxidized real diesel fuel has been investigated in a spiral micro-channel contactor. The solvent screening has been performed and dimethylformamide has demonstrated the best performance in sulfur removal and fuel recovery. In addition, the influence of channel size, channel length, sonication intensification approach, and multi-stage extraction on the sulfur removal have been studied. It was found that the desulfurization efficiency increased from 42.94% to 70.25% as the channel size decreased from 1.78 mm to 0.79 mm, which is due to the higher interfacial area in the smaller channel diameter. Also, the results showed that increasing the micro-channel length from 160 mm to 640 mm increased the sulfur removal from 52% to 85%, respectively. Moreover, the simultaneous effect of sonication and channel size on the desulfurization efficiency was investigated. It was shown that the sonicated contactor had higher desulfurization efficiency than the silent contactor in all channel diameters, and its performance intensification increased with the channel size. The enhancement ratio of the sonicated contactor rose from 5.81% to 16.82% by increasing the channel diameter from 0.79 mm to 1.78 mm. Furthermore, the multi-stage extraction has been performed and 97.57% sulfur removal was achieved.

Condensation heat transfer and pressure drop of R1234yf/HFC mixtures inside small diameter channels

Hydrofluoroolefin/hydrofluorocarbon mixtures, such as R1234yf/HFC mixtures, have been proposed for the substitution of R134a in refrigeration and air-conditioning applications. Indeed, these fluids present good thermodynamic properties and low environmental impact. Here, the condensation process of two mixtures, R513A (R1234yf/R134a 56/44% by mass) and R516A (R1234yf/R152a/R134a 77.5/14/8.5% by mass), has been investigated inside two channels with inner diameters equal to 0.96 mm and 3.38 mm. Both R513A and R516A are azeotropic mixtures. Condensation heat transfer tests have been conducted at 40 °C saturation temperature and mass flux ranging between 40 kg m−2 s−1 and 600 kg m−2 s−1. In the present study, particular focus is put onto condensation at low mass flux (below 100 kg m−2 s−1). Tests at low mass fluxes are very rare in the literature but of great relevance considering that chillers and heat pumps equipped with variable speed compressors work for most of their lifetime at partial loads, thus reducing the refrigerant mass flow rate in the heat exchangers and the mass flux in each channel as compared to the nominal working conditions. In the 3.38 mm diameter channel, the two-phase flow has been recorded using a high-speed camera and a comparison with two flow pattern maps is presented. The heat transfer coefficient data have been compared with the results of three semi-empirical models and with a specifically developed Artificial Neural Network model.

Multiple-open-tubular column enabling transverse diffusion. Part 3: Simulation of solute dispersion along a real three dimensional-printed column with quadratic channels

Multiple-open-tubular columns enabling transverse diffusion (MOTTD) consist of straight and parallel flow-through channels separated by a mesoporous stationary phase. In Part 1, a stochastic model of band broadening along MOTTD columns accounting for longitudinal diffusion, trans-channel velocity bias, and mass transfer resistance in the stationary phase was derived to demonstrate the intrinsic advantage of MOTTD columns over classical particulate columns. In Part 2, the model was refined for the critical contribution of the channel-to-channel polydispersity and applied to address the best trade-off between analysis speed and performance. In this Part 3, a MOTTD column with a square array of quadratic channels is fabricated by 3D-printing (combining polymer stereolithography with photolithography using photomasks) to deliver unprecedently small apparent channel diameters of 117.6 ± 5.0 μm. The colors in the microscopy photographs of the actual 3D-printed channels are binarized to delimitate the mobile phase volume from the stationary phase volume. The same numerical simulations as those in Part 2 are then performed for two MOTTD columns (external porosity ϵe=31.7%, same apparent channel diameter 117.6 μm): one containing 16 virtual perfect quadratic channels and the other 16 real 3D-printed channels. The reduced velocities (or Peclet numbers) are varied over a wide range from 0.2 to 5000 and the zone retention factors were fixed at k1=1.04, 5, and 25.The results demonstrate that smoothing the edges of the targeted quadratic channels by the 3D-printed technique is advantageous in terms of solute dispersion. It outperforms the negative effect of the channel-to-channel polydispersity which is mitigated by transverse diffusion of the analyte in the stationary phase. For Peclet numbers larger than 50, the HETP of the 3D-printed MOTTD column is found 7%, 15%, and 16% smaller than that of the MOTTD column consisting of a square array of perfect quadratic channels. This confirms the known effect of channel geometry on solute dispersion in microfluidic systems. Flow channels in fabricated MOTTD columns are preferred to be circular so that the distribution of transverse diffusion lengths across the open channels remains as tight as possible. Finally, the general theory of nonuniform columns of Giddings reveals that the polydispersity of the cross-sectional area (RSD 8.4%) along a single 3D-printed channel has no negative impact on solute dispersion in MOTTD columns. Overall, MOTTD columns could become a serious alternative technology to conventional particulate columns. This implies a novel fabrication process that delivers circular channel diameters smaller than 10 μm, cross-sectional area polydispersity no larger than 25%, external porosities in a range from 15% (high speed separations) to 75% (high performance separations), and conventional mesoporous silica as the stationary phase. It adresses new synthesis routes based on either organic fibers or tubular micelle templating agents in suspension with silica gel solutions.

Dynamic Synthesis of Three−Point Circle Peripheral Docking Technology Pose

Research on space docking technology was first motivated by the application scenario of space station docking in the aviation field. Due to the maturity of this technology, its application field is expanding to other industries. To benefit the intelligent transportation field, this study uses space docking technology to realize combination and reconstruction between car bodies. Different spatial docking methods and structural characteristics are determined by different application scenarios. The docking of the space station is completed in the suspended state of the body in the outer space environment, which requires advanced technology, is high in hardware cost, and involves a small channel diameter. In this study, the docking of the reconstructed vehicle is completed on the ground; thus, it is low in hardware cost and involves a large channel diameter. Based on the above technical requirements, a three−point circular peripheral docking method is designed for the reconstructed vehicle. A visual positioning system is built, the mapping relationship between the camera coordinate system and the landmark coordinate system rotation matrix and translation vector is established, and the adaptive capture behavior is realized by path planning through the inverse pose solution model. Simulation experiments demonstrate that the active and passive vehicle bodies can achieve compliance capture with small collision force under the two conditions of forward collision and oblique collision, and the recovery coefficient after collision and docking is in the range of (0, 0.01). The acceleration decay process under two working conditions is measured in the crash test of a sample vehicle, which verifies the feasibility of the space reconstruction of the vehicle docking mechanism and the ability of this configuration to achieve tasks, providing a constructive idea for space docking technology with a large channel diameter.

The use of PIV methods in the study of two-phase flows in small diameter channels

The PIV (Particle Image Velocimetry) method is one of the optical, non-invasive measurement methods for measuring fluid velocity and can be used in the study of two-phase gas-liquid flows to determine velocity fields. The velocity distribution of the liquid and gas phases influences the formation of two-phase flow structures and, consequently, the mechanisms of energy and moment exchange in the two-phase flow. The article concerns the application of the PIV method to the assessment of hydrodynamic phenomena occurring during two-phase flow realized in pipe minichannels with an internal diameter d > 2 mm. Fluorescent marker particles with a density close to that of water were used in the research. The preliminary tests were carried out on the adiabatic water-air mixture. The research aimed to check the applicability of PIV methods also in non-adiabatic flows. As a result of preliminary studies, velocity maps of the liquid phase, histograms and velocity profiles in the vertical section of the tested minichannel were obtained.

水平非円形細管内気液二相流のボイド率特性に関する研究

水平非円形細管内気液二相流のボイド率特性に関する研究

Additive Technology for Forming Channels with Galvanic-Mechanical Coatings

A new additive technology for forming channels with galvanic-mechanical coatings is considered. The technological process of combined electroplating and mechanical processing of small diameter channels is compiled. Rational technological modes are defined.

Condensation heat transfer of R1234ze(E) and its A1 mixtures in small diameter channels

R1234ze(E) has emerged in the recent years as low Global Warming Potential substitute for R134a in refrigeration and air-conditioning systems. As a drawback, R1234ze(E) is classified as a mildly flammable fluid (A2L class) and, in the search for non-flammable alternatives to R134a, hydrofluorocarbon/hydrofluoroolefin binary mixtures can be considered. In the present work, condensation tests are performed with R1234ze(E) and non-flammable binary mixtures R450A (R1234ze(E)/R134a at 58.0/42.0% by mass) and R515B (R1234ze(E)/R227ea at 91.1/8.9% by mass) inside two channels with inner diameter equal to 3.38 mm and 0.96 mm. R515B is an azeotropic mixture whereas R450A is a near-azeotropic blend (temperature glide 0.6 K at 40 °C). Heat transfer coefficients are measured at 40 °C saturation temperature and mass flux from 40 kg m−2 s−1 to 600 kg m−2 s−1. Flow pattern visualizations are recorded by a high-speed camera in the 3.38 mm inner diameter tube. Two-phase pressure gradients are measured in the 0.96 mm test section at mass flux equal to 200 and 400 kg m−2 s−1. The prediction accuracy of condensation heat transfer and two-phase pressure drop models is assessed against the experimental results. A comparative study between the tested fluids and R134a, accounting for both the heat transfer coefficients and the two-phase pressure drops, is performed.

Studies of critical heat fluxes in small diameter channels

The paper presents the results of experimental studies of critical heat flows in vertical small diameter channels, when the coolant moves from bottom to top, which were carried out in the Obninsk branch of MEPhI in the 1970s of the last century but have not become widespread due to the lack of demand for their practical use. Nowadays, the interest in such works is manifested, first of all, in the development of compact plants and devices, particularly in nuclear power engineering. As a coolant, water, Freon-12 and 96% ethyl alcohol were used. High velocities of underheated liquid at high heat fluxes on the channel wall lead to the so-called “fast crisis” of heat transfer. In this case, the magnitude of the heat flux depends mainly on the parameters of the coolant flow in the wall zone rather than the flow core. The “slow crisis” is mainly observed at high vapor concentrations, relatively low mass flow rates and in an annular-dispersed flow. The value of the critical heat flow in this case depends mainly on the flow parameters in the core, which are probably close to the average coolant flow parameters. The conditions in the near-wall region are also largely determined by the flow in the core. High heat transfer coefficients in a flow moving at high speed usually result in a much smaller and slower rise in the wall temperature. Sometimes a DNB heat flux can occur bypassing the boiling process. In the core of a VVER-type reactor operating in its nominal mode, surface boiling is present in a number of fuel rods. Probably, surface boiling will also be present in transportable and small-size nuclear power plants. Therefore, an important task is to conduct relevant research in this area.

Optimization of a Zigzag-channel printed circuit heat exchanger for supercritical methane flow

Printed circuit heat exchanger (PCHE) is a compact plate heat exchanger that etches microchannels on plates by chemical etching method and exploits bonding force between the atoms to achieve diffusion bonding. It has the promising applications in the fields of floating liquefied natural gas, nuclear reactor, hydrogen energy, etc. The influence of structural parameters on flow and heat transfer characteristics in a Zigzag-channel PCHE was investigated using supercritical methane as flow media. Three-dimensional turbulent steady numerical method was determined and verified through the SST k-ω turbulent model in FLUENT platform. The influence mechanism of structural parameters on flow and heat transfer characteristics was analyzed from temperature distribution, turbulent dissipation rate, vortex vector, turbulent intensity and helicity. The results indicated that the worse flow and better heat transfer performance exhibited under the condition with small channel diameter, small pitch and large bending angle. Meanwhile, the optimization analysis was also conducted though the coupling consideration of flow and heat transfer performances of PCHE using thermal performance factor (TPF). The optimum channel was obtained with the diameter, channel pitch, and bending angle of 1.427 mm, 24.6 mm, and 15° respectively, in scope of this study. The optimum structure parameters obtained herein will be instructive in the design of PCHE.

Study of Pressure Drops and Heat Transfer of Nonequilibrial Two-Phase Flows

Currently, there are no universal methods for calculating the heat transfer and pressure drop for a wide range of two-phase flow parameters in mini-channels due to changes in the void fraction and flow regime. Many experimental studies have been carried out, and narrow-range calculation methods have been developed. With increasing pressure, it becomes possible to expand the range of parameters for applying reliable calculation methods as a result of changes in the flow regime. This paper provides an overview of methods for calculating the pressure drops and heat transfer of two-phase flows in small-diameter channels and presents a comparison of calculation methods. For conditions of high reduced pressures pr = p/pcr ≈ 0.4 ÷ 0.6, the results of own experimental studies of pressure drops and flow boiling heat transfer of freons in the region of low and high mass flow rates (G = 200–2000 kg/m2 s) are presented. A description of the experimental stand is given, and a comparison of own experimental data with those obtained using the most reliable calculated relations is carried out.