Transfer Drop Research Articles

Optimization and heat transfer correlations development of zigzag channel printed circuit heat exchangers with helium fluids at high temperature

The printed circuit heat exchanger (PCHE) is an important candidate to be used as intermediate heat exchanger (IHX) in a High Temperature Gas-cooled Reactor (HTGR) plant due to its advantages in terms of safety, heat transfer and compactness. In this work, an analysis of the thermal-hydraulic performance of the zigzag channel PCHE within wide parameter ranges was conducted using computational fluid dynamics (CFD) techniques. The Nusselt number and the Fanning friction factor obtained from simulation were validated using experimental data available. To consider the interaction among parameters with a reduced computing time, the Taguchi method was used, which reduces the quantity of analyzed geometric designs. Optimized designs were proposed to reach the highest Nusselt number and lowest friction losses using the signal to noise ratio as objective function. It was found that the zigzag angle has contribution ratios around 50% and 70% on the values of pressure drop and heat transfer, respectively. Although the zigzag phase-shift was the parameter of least influence, its contribution ratio was close to 10% in the turbulent regime, which is comparable to the zigzag pitch length and bend radius contributions. As the most important contribution, Nusselt number and Fanning friction factor correlations were proposed as functions of the Reynolds number and the geometrical parameters. The new correlations were found to be more accurate as compared to existing ones in the literature.

THERMO-HYDRAULIC PERFORMANCE ANALYSIS OF PARABOLIC CONCENTRATING SOLAR WATER HEATER

This paper concerns the thermo-hydraulic performance analysis of a PCSWH (parabolic concentrating solar water heater) with placing the PTT (perforated twisted tape) in the absorber tube. The experiments are performed using water as testing fluid. In this analysis, the mass flow rate changes from 0.0326 kg/s to 0.0667 kg/s and Reynolds number ranges from 2100 to 4250 respectively. The analysis is based on the effect of porosity of the PTT and mass flow rate over the pressure drop and heat transfer enhancement during the flow into the absorber tube of the PCSWH. At last to guess the increment in pressure drop and enhancement of heat transfer the empirical correlations for friction factor and the Nusselt number have been formulated considering the turbulent effect caused by PTT inside the absorber tube. The major observations of this analysis are that PTT enhances the pressure drop and heat transfer and also both enhances with increasing porosity of the PTT.

Heat transfer and pressure drop in a sinus blowing of copper oxide- water non-Newtonian nanofluid in a sudden expansion process in the presence of variable magnetic field: a numerical solution

ABSTRACT In the current article, the effect of nanofluid blast on the forced convection heat transfer in the intra-channel turbulent flow with a sudden expansion is investigated. The different cases of Newtonian, non-Newtonian, and incompressible fluids have been studied. The effects of non-Newtonian fluid index, magnetic field, nanoparticle volume fraction and nanofluid blowing frequency parameters on the pressure drop and heat transfer in the intra-channel flow have been reviewed. The simulation was performed using finite volume method as the solution strategy. The results revealed that higher values of Re and nanoparticles volume fraction resulted in the Nusselt number increasement. Also, increasing the magnetic field and decreasing the non-Newtonian fluid index increased the forced heat transfer coefficient and subsequently the Nusselt number. The results showed that the sinus velocity caused to increase the rate of the heat transfer and slightly lower friction coefficient. However, higher frequencies caused increasing of heat transfer and friction coefficient. Finally, it was founded that higher values of the Re had the most influence on the performance of the system and the magnetic field and sinus velocity were in the next step.

Numerical Analysis of FLiBe Laminar Convective Heat Transfer Characteristics in Tubes Fitted With Coaxial Cross Twisted Tape Inserts

Molten salts are now widely used as heat transfer fluids in solar thermal plants and molten salt nuclear reactors. In order to explore its heat transfer enhancement method, new coaxial cross twisted tapes (CCTTs) are applied to plain tube with molten salt FLiBe as working fluid, and the characteristics of pressure drop and heat transfer are numerically investigated by the CFD software STAR-CCM+. Simulations are performed in a laminar flow regime where Reynolds number ranges from 100 to 1100, and the velocity, temperature profiles, and enhanced performance evaluation criteria (PEC) are analyzed to investigate the heat transfer performance of FLiBe in the tube fitted with CCTTs and typical twisted tape (TT). Water and lubricating oil are also researched to investigate the effects of fluid thermal-physical properties on the performance of CCTTs. The results show that CCTTs can produce stronger swirl flow and greatly enhance heat transfer. For overall heat transfer performance, the maximum PEC of FLiBe with CCTTs reaches 2.37. The comparison of three different fluids also indicates that CCTTs have better heat transfer performance for higher Prandtl number fluids such as molten salt. The correlations of CCTTs and TT are developed into a unified form for the prediction of friction factors and Nusselt numbers for various Prandtl number fluids.

Evaluation of performance improvements through application of anisotropic foam packings in rotating packed beds

Constantly increasing interest in HIGEE technology and rotating packed beds require detailed investigations of the mass transfer and hydrodynamic performance. Classical isotropic single block packings constitute the most applied and investigated packings for absorption and stripping processes. Yet, the large geometric surface area which is offered by these packings can hardly be exploited to the full extent due to the constant change in gas and liquid loads along the radius of the annular packings. In order to overcome these limitations and extend the operating range and mass transfer performance of foam packings, the current study presents a detailed comparison of isotropic and anisotropic packings. The conducted pressure drop and mass transfer experiments, based on chemical absorption of CO2 with aqueous sodium hydroxide, illustrate the improved performance that can be expected from anisotropic packings, while dedicated gamma-ray computed tomography provides further insight into the improved liquid distribution for this kind of packings.

Determination of Parameters of Electrode Metal Transported Drops by Simulation and Visualization

The nature of the molten electrode metal melting and transfer is the main process parameter of manual metal arc welding (MMA) with coated electrodes. It significantly affects the efficiency of the welding process. For this reason the relevant task is to identify the parameters of the transferred molten electrode metal drops and their further transfer into the weld pool with maximum accuracy. The aim of the given paper is to develop a method and visual representation of the form and the geometrics (volume, area, mass) of a molten electrode metal drop.We have developed the method of simulation modeling and visualization for molten electrode metal drops transfer and their parameters. It allows obtaining highly reliable input data to be used for developing and verification of mathematical models for the thermal fields distribution along the welded item surface. The algorithm is realized as the calculation programs for specifying the molten metal drop parameters and means of its geometrics and space form visualization.We used this method to specify a number of molten electrode metal drop parameters: volume, mass, center-of-gravity position, surface area.We have established that it is possible to conduct the measurements with maximumThe suggested method significantly decreases the labor intensity of experimental studies aimed at specifying the size of electrode metal drops in comparison to the standard methods. When we know the size of the drops under certain welding conditions we can control the drop transfer process, i. e. reduce the heat input into the welded item and produce weld joints with the tailored performance characteristics.

The K number, a new analogy criterion number to connect pressure drop and heat transfer of sCO2 in vertical tubes

Pressure drop and heat transfer are important for design and operation of power plant using supercritical fluid, but they were investigated independently previously. The objective of this paper is to make a connection between pressure drop and heat transfer for supercritical carbon dioxide (sCO2). Experimental data of pressure drop and heat transfer were obtained in our sCO2 convective test loop, covering pressures, mass fluxes and heat fluxes in the ranges of 7.5–23 MPa, 500–1500 kg/m2s and 15–400 kW/m2, respectively. Different from classical single-phase fluid assumption for supercritical fluid, pseudo-boiling is introduced to deal with flow and heat transfer in supercritical domain, including a wall-attached gas-like layer and a liquid-like fluid in tube core. Supercritical boiling number SBO and K number are developed to characterize the gas-like layer thickness. Friction factors and heat transfer are found to display the two regimes distribution: a normal heat transfer (NHT) regime with smaller friction factors at smaller SBO, and a heat transfer deterioration (HTD) regime accompanying sharply increased pressure drops beyond a critical SBO. We conclude an orifice contraction effect due to the strong vapor expansion, explaining the HTD induced rise of pressure drops. We show that K can be the similarity criterion number to connect pressure drops and heat transfer. A new correlation of friction factors is developed for sCO2, which is suitable for NHT and HTD, having mean relative error, mean absolute relative error and root-mean-square relative error of −6.2%, 18.1% and 21.2%, respectively, which are significantly smaller than those predicted by the correlations in the literature.

Optimization of heat transfer in a grooved pipe model by Stochastic Algorithms and DOE based RSM

Additive manufacturing is a promising candidate to eliminate design constraints in thermal-fluid engineering problems as it enables optimized free-form designs to be produced. The brute force optimization needs too many experiments and/or analyses to obtain an optimized design. However, the same engineering design can be achieved by fewer experiments by using design of experiment (DOE) methodology, which minimizes the work load. In this study, local and mean heat transfer coefficients for a grooved pipe model are optimized and the system constraints are determined in compatible with the additive manufacturing method. DOE based response surface methodology (RSM) and an in-house developed optimization code are used to obtain the optimal local and mean heat transfer coefficients. The analyses are performed for both laminar and turbulent flow cases for understanding the backward and forward effects of grove dimensions better. The comparison of the recirculation regions in the groove geometries for optimal cases of laminar and turbulent flows reveals that the grooves in the pipe do not have to be uniform along the streamwise direction to obtain optimal heat transfer for local needs. This optimization approach provides both local and global controllability of heat transfer and the heat transfer values can be increased up to 20% in this thermal-fluid engineering problem. In addition, pressure drop and heat transfer contribution ratio of each grooved section are presented in detail.

Numerical Analysis on Pressure Drop and Heat Transfer in Nanofluids at Pore Length Scale in Open Metal Porous Structures with Kelvin Cells

In this paper, a numerical investigation in metal porous structures with Kelvin cell model is carried out on water/Al2O3 nanofluids using the single-phase model. The examined foams are characterized by a porosity of 0.95 and different values of cells per inch (CPI), equal to 10 and 20 CPI. Three different values of Al2O3 nanoparticle volume concentrations equal to 0, 2 and 4% are used. Results are presented and discussed in terms of pressure drop between the inlet and outlet sections. Furthermore, it has been possible to obtain a correlation used to find the value of permeability and drag coefficient for metal porous structures under investigation. It has been possible to notice how these two properties of the foam do not depend on the type of fluid but only on the geometric properties. In addition, the interfacial heat transfer coefficient between the fluid phase and the solid matrix has been estimated. In conclusion, the results in terms of Nusselt number as a function of Reynolds number based on the struct diameter show that it does not change varying the CPI values.

Dynamic behaviour of a plate heat exchanger: Influence of temperature disturbances and flow configurations

Understanding the dynamic properties of a plate heat exchanger plays an essential role when developing smart control algorithms for modern energy-efficient district heating and cooling applications. In this work, the dynamic behaviour of a counterflow plate heat exchanger is studied in order to understand its transient responses due to inlet temperature disturbances at different fluid flow configurations. For this purpose, a suitable theoretical model has been proposed. The temperature transients are evaluated numerically by solving a lumped-parameter system representing the derived 1D model of the studied plate heat exchanger. The numerical results revealed that different fluid flow configurations considerably influence the transient temperature responses as well as the overall temperature drop and heat transfer rate when following the cold down process of a fluid travelling from the inlet to the outlet of the plate heat exchanger hot fluid side. The predicted transients are experimentally verified by conducting a series of systematic tests using infrared thermography technology. The analysis shows that the proposed model is in good agreement with the experiments. The results of the thermal imaging measurements also provide a more in-depth insight into the temperature distribution and its transient front propagation along the fluid flow channels. In future studies, such an experimental approach is valuable to identify the critical temperature zones when predicting the thermal fatigue life-time of brazed plate heat exchangers and as well to extend the proposed theoretical model to include the 2D local heat transfer coefficient distribution obtained by the IR thermography.

Computational and statistical analysis on the U‐tube heat exchanger with different passes configuration: Taguchi method

AbstractIn the present study, the passive technique of heat transfer in which single pass and double passes are included in a simple U‐tube heat exchanger is analyzed. The computational fluid dynamics (CFD)‐based parametric analysis is carried out to optimize the parameters affecting the temperature drop and heat transfer achieved from the U‐tube heat exchanger. ANSYS Fluentv20 is used for the CFD analysis, and the RNG k‐ɛ model and energy equation were considered to define the turbulence and heat transfer phenomena. The Taguchi method is used to formulate the experimental work and analyze the working parameters of the U‐tube heat exchanger, such as hot and cold mass flow rate and hoRenew Energyt inlet temperature and cold inlet temperature. For the U‐tube heat exchanger, four operating parameters are considered at four different levels in the Taguchi method. The best combination of parameters for achieving a maximum temperature drop is A4B1C2D3, and it is A3B4C1D2 in case of heat transfer. A U‐tube single‐pass heat exchanger is more effective as compared with other U‐tube heat exchangers (zero‐ and double‐pass). Experimental results are provided to validate the suitability of the purpose of the approach.

Thermo-hydraulic analysis of compact heat exchanger for a simple recuperated sCO2 Brayton cycle

Supercritical carbon dioxide (sCO2) Brayton cycle-based power plants are being extensively explored as viable alternatives to traditional Rankine based steam power plants. Higher temperatures at the turbine exit in a sCO2 cycle provide better opportunities for heat recuperation, thus improving overall cycle efficiency. Among the various heat exchanger configurations available, compact microchannel heat exchangers commonly known as Printed Circuit Heat Exchangers (PCHE's) are typically used in sCO2 power plants. In the current work, a hybrid approach comprising of a Thermal Resistance Network (TRN) model coupled with a CFD model for estimating local heat transfer and pressure drops is presented for a PCHE core with straight and zigzag channel configurations. Full-scale TRN model is used to optimize the overall stack dimensions based on minimum rate of heat loss from the external surfaces of the PCHE core. The TRN model accounts for the thermo-physical property variations of sCO2 along the channel length to effectively capture the channel pressure drop and heat transfer. This is achieved by discretizing the heat transfer domain comprising of alternatively stacked hot and cold streams into sub-heat exchangers to account for variations in thermophysical properties while calculating the nodal friction factors and local heat transfer coefficients. CFD simulations are performed for a full length of a single stack of hot and cold fluid streams to arrive at corrected heat transfer and pressure drop correlations. Thermo-hydraulic analysis is performed for a range of channel hydraulic diameters and channel mass flow rates for both straight and zig-zag configurations to deduce optimum stack dimensions. The efficacy of the hybrid model is demonstrated with a case study of a counterflow recuperator used in a simple recuperated 1 MW sCO2 Brayton power plant.

Using expansion units to improve CO2 absorption for natural gas purification - A study on the hydrodynamics and mass transfer

Abstract The usage of capillary tubes for CO2 absorption suffers from small residence time, which leads to reduced performance for large throughput. This work presents a method of connecting expansion units to capillary tubes to serve as a residence time delayer. The effect of the expansion unit on gas–liquid hydrodynamics, pressure drop and mass transfer coefficient (kLa) are investigated under various operating pressures up to 4.0 MPa, for both physical and chemical absorption. A novel periodic jetting flow is found in the expansion unit, which can intensify the CO2 absorption. Experimental results show that the strategy can significantly decrease the pressure drop while maintaining the absorption performance to a large extent. The overall kLa for physical and chemical absorption are correlated to pressure drop, respectively. Besides, CO2 loading in rich absorbents increases dramatically compared to literature studies with only micromixers or capillary tubes, which is beneficial to regenerate solvent. The study verifies the concept that pre-treatment with water can largely reduce the usage of amines, and can also provide a guide for process design in natural gas purification such as biogas recovery.

Experimental and numerical analysis of thermal flow in open-cell porous metal during Darcy-Forchheimer transition regime

A numerical analysis of pressure drop and heat transfer for open-cell porous media is performed using a three-dimensional conjugate heat transfer model. Porous metal with a pore density of 20 pores per inch (PPI) and porosity of 95.7% is used in the present numerical simulation. Real microstructure of the open-cell porous metal is constructed using stacked images obtained by X-ray computed tomography method. Computed thermal-fluid characteristics are compared directly with the experimental pressure drop and unit overall thermal resistance values. The flow through porous metal can be divided into the Darcy regime and the Forchheimer regime. The thermo-fluidic characteristics in the Darcy regime and the Forchheimer regime are investigated numerically. The flow separation is not observed in the Darcy regime, but the wake region occurs in the Forchheimer regime because of the flow separation on the ligament surface. The contribution of the total drag acting on the walls (top & bottom) is very small, namely, less than 5% compared to the total drag on ligaments. The total drag force coefficient of ligaments tends to converge at high Reynolds number. This is because the pressure drag force is dominant due to the wake effect in the Forchheimer regime. Local Nusselt number is large near the upstream side of the ligament and very low in the wake region. Average Nusselt number increases with Reynolds number. In the Forchheimer regime, wakes developed behind ligaments increase the pressure loss and decrease the heat transfer performance.

Numerical investigation of thermal and hydraulic characteristics of sCO2-water printed circuit heat exchangers with zigzag channels

Since the precooler and the recuperator are the largest components of a supercritical carbon dioxide Brayton cycle, their design can substantially affect the performance and size of the whole system. Although the design of a precooler with zigzag channel geometry as an alternative to straight channels can reduce its size significantly, the applicability of available correlations (e.g. 0.7 < Pr<2.2) for the zigzag channel geometries is limited to the operational range of recuperators only. The current study, therefore, aims to develop correlations and understating of the complex flow and heat transfer characteristics in the zigzag channel printed circuit heat exchangers (PCHEs) operating under precooler conditions (2.2<Pr<13) of supercritical carbon dioxide Brayton cycle(sCO2-BC). Thermal and hydraulic characteristics of the PCHEs are computed numerically for a wide range of Reynolds numbers (5000<Re<7000) and Prandtl number (2.2<Pr<13). Also, a new data reduction method based on segmental averaged values has been proposed to handle adverse variations in the thermophysical properties of CO2 under precooler conditions. To ensure accurate evaluations, steep variations in the thermophysical properties of CO2 are implemented by supplying high-resolution real gas (RGP) property tables. Results suggest that thermal and hydraulic characteristics associated with zigzag channel vary substantially along the length of heat exchanger thus the conventional data reduction methods based on the channel average values cannot be used for true evaluations. Instead, segmental average values are used to develop pressure drop and heat transfer correlations for a broader range of Reynolds number and Prandtl number. The proposed correlations should be useful in the design of compact heat exchanger systems using zigzag channels for a wider range of cooling loads.

Characteristics of evaporation of propane (R290) in compact smooth and microfinned tubes

Evaporation of flowing propane and the effect of enhanced geometry on heat transfer coefficient and pressure drop is experimentally investigated. One smooth tube and two microfinned tubes with an outer diameter of 5 mm were tested. Heat transfer coefficient and pressure drop were determined for saturation temperatures of 0, 5 and 10 °C for smooth tube, and the effect of using tubes with enhanced geometries was evaluated at heat fluxes ranging between 15 and 33 kW m−2 and mass fluxes between 250 and 500 kW m−2 s−1. The increase of heat transfer coefficient for microfinned tubes relative to smooth tube diminishes with increasing mass flux, while the increase of pressure drop remains unaffected. Comparison of the experimental results with correlations for prediction of pressure drop and heat transfer coefficient demonstrates availability of reliable correlations. Nevertheless, correlations show considerable divergence in accuracy for different microfinned tubes.

Dynamic Performance of Various Thermal Energy Storage Materials

The thermal effects of metal partitions inside Porous Thermal Energy Storage (PTES) have been investigated experimentally and theoretically. Four circular cross-sectional area matrices have been studied and comparison was made between them. These include; storage with Flat Plate partitions (FP), storage with Corrugated Plate partitions (CP), storage with Wire Mesh partitions (WM), and storage Without Partitions (WP). A numerical model has been developed to simulate dynamic thermal energy transfer within (PTES) to include the important thermal effects of the partitions within porous matrices. The developed numerical model is characterized by system of differential energy conservation equations, these equations are solved numerically by time marching implicit method. The theoretical analysis and computational scheme validity has been verified through comparisons with measured data from the experimental work conducted in this work. The investigation has been done for Reynolds number, Re, of 1270 <Re < 8050. A convenient agreement was found between theoretical and experimental results for all of the tested matrices. The metal partitions were specified to have considerable effect on the thermal response for each type of the tested materials. From the comparison of different matrices concerning their ratio between pressure drop and heat transfer, it was found that the (CP) matrix has the highest performance. In this work, an improved transient method was presented for the calculation of the average heat transfer coefficient for porous flow channels along the axial direction with the thermal effects of the metal partitions. A correlation equation been developed for the J-factor have for each matrix material at the range of Reynold’s number under investigation. The new (three) correlations predicting the J-factor are found to be in reasonable agreement with the limited published data. However, these correlations have been included the effect of the inside partitions, which have been ignored in all previous published data.

Role of Supercritical Nitrogen (SCN) on the hydraulic and thermal characteristics of futuristic High Temperature Superconducting (HTS) cables

Cryogenic fluids such as Liquid Helium (LHe), Liquid Nitrogen (LN2), Liquid Oxygen (LOX) and Liquid Hydrogen (LH2) played a vital role in cooling various superconducting devices. The boiling temperatures of cryogenic fluids being lower than the critical temperature of the superconductors have enabled such an advantage. Moreover, supercritical fluids such as Supercritical Helium (SHe) and Supercritical Nitrogen (SCN) are also found to be replacing the liquid coolants thereby eliminating the possibility of reduction in heat transfer due to multiphase flow of working fluid. Hence, it is essential to investigate the role of such supercritical fluids in cooling the superconducting cables. Hence, in the present work, Super Critical Nitrogen (SCN) is proposed as a coolant for cooling of High Temperature Superconducting (HTS) cables. As the thermophysical properties are strongly affected by the temperature, analytical functions of thermophysical properties of SCN such as viscosity, density, specific heat and thermal conductivity are developed and implemented in the Thermohydraulic analysis of 1 m HTS cable. A 3-Dimensional computational model of HTS cable is modeled and developed in commercial software ANSYS-FLUENT for solving governing equations of mass, momentum and energy simultaneously. Different mass flow rates ranging from 16 L/min to 20 L/min and heat loads ranging from 1 W/m to 3 W/m are considered in estimating the thermohydraulic performance of HTS Cable. Friction factor, pressure drop, pumping power and heat transfer rate are estimated and compared with the results of experiments available in the literature. It can be concluded that SCN may be used as coolant to cool the HTS cables having higher critical temperature.

Design complexity and performance analysis in additively manufactured heat exchangers

The main objective of this research is to investigate the tradeoffs between design complexity and thermal performance in additively manufactured metallic heat exchangers. Such heat exchangers have become a favorite topic for investigation in various fields ranging from air conditioning to aircraft gas turbine engines. In particular, high manufacturing cost has emerged as the major drawback in broad applications of manifold-microchannel heat exchanger (MMHXs). The possibility of cost-effective manufacturing has generated wide interest in applying additive manufacturing (AM) for fabricating MMHXs. Furthermore, AM technologies will provide an opportunity for enhanced design and superior heat transfer performance. In this study, innovative MMHXs are designed and fabricated through selective laser melting. An experimental setup was designed to measure pressure drop and heat transfer for the developed MMHXs with a wide range of Reynolds numbers. The coefficient of performance was calculated based on the heat flow rate, air pressure drop, and air flow rate. Measurement results demonstrated that in some scenarios adding more internal features, i.e., increasing design complexity, does not necessarily improve the MMHX performance.

Thermal and Manufacturing Design Considerations for Silicon-Based Embedded Microchannel-3D Manifold Coolers (EMMCs): Part 1—Experimental Study of Single-Phase Cooling Performance With R-245fa

Abstract High performance and economically viable cooling solutions must be developed to reduce weight and volume, allowing for a wide-spread utilization of hybrid electric vehicles. The traditional embedded microchannel cooling heat sinks suffer from high pressure drop due to small channel dimensions and long flow paths in two-dimensional (2D) plane. Utilizing direct “embedded cooling” strategy in combination with top access three-dimensional (3D) manifold strategy reduces the pressure drop by nearly an order of magnitude. In addition, it provides more temperature uniformity across large area chips and it is less prone to flow instability in two-phase boiling heat transfer. This study presents the experimental results for single-phase thermofluidic performance of an embedded silicon microchannel cold plate (CP) bonded to a 3D manifold for heat fluxes up to 300 W/cm2 using single-phase R-245fa. The heat exchanger consists of a 5 × 5 mm2 heated area with 25 parallel 75 × 150 μm2 microchannels, where the fluid is distributed by a 3D-manifold with four microconduits of 700 × 250 μm2. Heat is applied to the silicon heat sink using electrical Joule-heating in a metal serpentine bridge and the heated surface temperature is monitored in real-time by infrared (IR) camera and electrical resistance thermometry. The maximum and average temperatures of the chip, pressure drop, thermal resistance, and average heat transfer coefficient (HTC) are reported for flow rates of 0.1, 0.2. 0.3, and 0.37 L/min and heat fluxes from 25 to 300 W/cm2. The proposed embedded microchannels-3D manifold cooler, or EMMC, device is capable of removing 300 W/cm2 at maximum temperature 80 °C with pressure drop of less than 30 kPa, where the flow rate, inlet temperature, and pressures are 0.37 L/min, 25 °C and 350 kPa, respectively. The experimental uncertainties of the test results are estimated, and the uncertainties are the highest for heat fluxes &amp;lt; 50 W/cm2 due to difficulty in precisely measuring the fluid temperature at the inlet and outlet of the microcooler.