Wave behavior in horizontal annular air–water flow

In this study, non-intrusive pressure drop, liquid base film thickness distribution, and wave behavior measurements have been obtained for 206 horizontal annular two-phase (air–water) flow conditions in 8.8, 15.1, and 26.3 mm ID tubes. Reliable wave velocity measurements are available for 185 of these flow conditions, while 131 flow conditions allow for reliable wave frequency measurements. The wave velocity is found to be predicted to within 9% by gas friction velocity and 6% by an optimized correlation of similar structure. Wave frequency can also be predicted with a simple correlation to within 5% for the 8.8 and 15.1 mm tubes, but a separate relation is required to explain 26.3 mm frequency data. The differences in wave behavior between the annular and wavy-annular/wavy regimes are also discussed.     

Flow regimes and two-phase pressure gradient in horizontal straight tubes: Experimental results for HFO-1234yf, R-134a and R-410A

Two-phase flow regime visualizations of HFO-1234yf and R-134a in a 6.70 mm inner diameter glass straight tube have been simultaneous investigated by top and side views with a high speed high resolution camera. No major difference was observed between both refrigerants. HFO-1234yf flow regimes were satisfactorily predicted by the Wojtan et al. [1] flow pattern map. In addition, 819 pressure drop data points measured during two-phase flow of refrigerants HFO-1234yf, R-134a and R-410A in horizontal straight tubes are presented. The tube diameter (D) varies from 7.90 to 10.85 mm. The mass velocity ranges from 187 to 1702 kg m⁻² s⁻¹ and the saturation temperatures from 4.8 °C to 20.7 °C. The results are compared against 10 well-known two-phase frictional pressure drop prediction methods. For the entire database, the best accuracy is given by the method of Müller-Steinhagen and Heck [2] with around 90% of the data predicted within a ±30% error band. An analysis was carried out on the maximum pressure gradient and on the corresponding vapor quality. A statistical analysis for each flow regime was also carried out.     

Visualization of flow boiling of liquid nitrogen in a vertical mini-tube

The flow boiling patterns of liquid nitrogen in a vertical mini-tube with an inner diameter of 1.931 mm are visualized with a high-speed digital camera. The superficial gas and liquid velocities are in the ranges of 0.01–26.5 m/s and 0.01–1.2 m/s, respectively. Four typical flow patterns, namely, bubbly, slug, churn and annular flow are observed. Some interesting scenes about the entrainment and liquid droplet deposition in the churn and annular flow, and the flow reversal with the indication of negative pressure drop, are also presented. Based on the visualization, the two-phase flow regime maps are obtained. Compared with the flow regime maps for gas–water flow in tubes with similar hydraulic diameters, the region of slug flow in the present study reduces significantly. Correspondingly, the transition boundary from the bubbly flow to slug flow shifts to higher superficial gas velocity, and that of churn to annular flow moves to lower superficial gas velocity. Moreover, time-averaged void fraction is calculated by quantitative image-digitizing technique and compared with various prediction models. Finally, three kinds of oscillations with long-period and large-amplitude are found, possible explanation for the oscillations is given by comparing the instantaneous flow images with the data of pressure, mass flux and temperature recorded synchronously.     

Prediction of the entrained liquid fraction in vertical annular gas–liquid two-phase flow

The study considers the prediction of the entrained liquid fraction in adiabatic gas–liquid annular two-phase flow in vertical pipes. Nine empirical correlations have been tested against an experimental data bank drawn together in this study containing 1504 points for 8 different gas–liquid combinations and 19 different tube diameters from 5.00 mm to 57.1 mm. The correlation of Sawant, Ishii and Mishima and the one of Oliemans, Pots and Trompé were found to best reproduce the available data. A new correlating approach, derived from both physical intuition and dimensional analysis and capable of providing further physical insight into the liquid film atomization process, was proposed and worked better than any of the existing methods. This new correlation is based on the core flow Weber number that is also a controlling dimensionless group in determining the wall shear stress and associated frictional pressure gradient of annular flows.     

Pressure drop prediction in annular two-phase flow in macroscale tubes and channels

A new prediction method for the frictional pressure drop in annular two-phase flow is presented. This new prediction method focuses on the aerodynamic interaction between the liquid film and the gas core in annular flows, and explicitly takes into account the asymmetric liquid film distribution in the tube cross section induced by the action of gravity in horizontal tubes operated at low mass fluxes. The underlying experimental database contains 6291 data points from the literature with 13 fluid combinations (both single-component saturated fluids such as water, carbon dioxide and refrigerants R12, R22, R134a, R245fa, R410a, R1234ze, and two-component fluids such as water-argon, water-nitrogen, alcohol-argon, water plus alcohol-argon and water-air), vertical and horizontal tubes and annuli with diameters from 3 mm to 25 mm, and both adiabatic and evaporating flow conditions. The new prediction method is very simple to implement and use, is physically based and outperforms existing pressure drop correlations (mean absolute error of 12.9%, and 7 points out of 10 captured to within ±15%).     

Algebraic turbulence modeling in adiabatic and evaporating annular two-phase flow

The study considers algebraic turbulence modeling in adiabatic and evaporating annular two-phase flow, focusing in particular on momentum and heat transfer (so-called ‘convective boiling’) through the annular liquid film. In contrast with single-phase wall-bounded flow theory, shear-driven annular liquid films are assumed here to behave as fluid-bounded flows, mostly interacting with the shearing gas-entrained droplets core flow. Besides providing velocity and temperature profiles through the liquid film, the turbulence model proposed here predicts key parameters such as the average liquid film thickness, the void fraction and the convective boiling heat transfer coefficient with accuracies comparable or better than those of leading design correlations. This turbulence model is part of a unified annular flow modeling suite that includes methods to predict the entrained liquid fraction and the axial frictional pressure gradient. The underlying heat transfer database covers nine fluids (water, two hydrocarbons and six refrigerants) for vertical and horizontal tubes of 1.03-14.4 mm diameter and pressures of 0.1-7.2 MPa. Importantly, this study shows that there appears to be no macro-to-microscale transition when it comes to annular flow. Simply better physical modeling is required to span this range.     

Flow regime transition criteria for two-phase flow at reduced gravity conditions

Flow regime transition criteria are of practical importance for two-phase flow analyses at reduced gravity conditions. Here, flow regime transition criteria which take the frictional pressure loss effect into account were studied in detail. Criteria at reduced gravity conditions were developed by extending an existing model from normal gravity to reduced gravity conditions. A comparison of the newly developed flow regime transition criteria model with various experimental datasets taken at microgravity conditions showed satisfactory agreement. Sample computations of the model were performed at various gravity conditions, such as 0.196, 1.62, 3.71 and 9.81 m/s² corresponding to micro-gravity and lunar, Martian and Earth surface gravity, respectively. It was found that the effect of gravity on bubbly–slug and slug–annular (churn) transitions in a two-phase flow system was more pronounced at low liquid flow conditions, whereas the gravity effect could be ignored at high mixture volumetric flux conditions. While for the annular flow transitions due to flow reversal and onset of droplet entrainment, higher superficial gas velocity was obtained at higher gravity level.     

Flow patterns and heat transfer in vertical upward air–water flow with surfactant

Flow patterns, the pressure drag reduction and the heat transfer in a vertical upward air–water flow with the surfactant having negligible environmental impact were studied experimentally in a tube of 2.5 cm in diameter. Visual observations showed that gas bubbles in the air–water solution with surfactant are smaller in size but much larger in number than in pure air–water mixture, at the all flow regimes. The transition lines in the flow regime map for the solution of air–water mixture with surfactant of the 300 ppm concentration are mainly consistent with the experimental data obtained in clear air–water mixture. An additive of surfactant to two-phase flow reduces the total pressure drop and decrease heat transfer, especially in the churn flow regime.     

Studies on two-phase co-current air/non-Newtonian shear-thinning fluid flows in inclined smooth pipes

In this work, co-current flow characteristics of air/non-Newtonian liquid systems in inclined smooth pipes are studied experimentally and theoretically using transparent tubes of 20, 40 and 60 mm in diameter. Each tube includes two 10 m long pipe branches connected by a U-bend that is capable of being inclined to any angle, from a completely horizontal to a fully vertical position. The flow rate of each phase is varied over a wide range. The studied flow phenomena are bubbly flow, stratified flow, plug flow, slug flow, churn flow and annular flow. These are observed and recorded by a high-speed camera over a wide range of operating conditions. The effects of the liquid phase properties, the inclination angle and the pipe diameter on two-phase flow characteristics are systematically studied. The Heywood–Charles model for horizontal flow was modified to accommodate stratified flow in inclined pipes, taking into account the average void fraction and pressure drop of the mixture flow of a gas/non-Newtonian liquid. The pressure drop gradient model of Taitel and Barnea for a gas/Newtonian liquid slug flow was extended to include liquids possessing shear-thinning flow behaviour in inclined pipes. The comparison of the predicted values with the experimental data shows that the models presented here provide a reasonable estimate of the average void fraction and the corresponding pressure drop for the mixture flow of a gas/non-Newtonian liquid.     

Flow regime development analysis in adiabatic upward two-phase flow in a vertical annulus

In this work radial and axial flow regime development in adiabatic upward air-water two-phase flow in a vertical annulus has been investigated. Local flow regimes have been identified using conductivity probes and neural networks techniques. The inner and outer diameters of the annulus are 19.1 mm and 38.1 mm, respectively. The equivalent hydraulic diameter of the flow channel, D_H, is 19.0 mm and the total length is 4.37 m. The flow regime map includes 1080 local flow regimes identifications in 72 flow conditions within a range of 0.01 m/s < 〈j_g〉 < 30 m/s and 0.2 m/s < 〈j_f〉 < 3.5 m/s where 〈j_g〉 and 〈j_f〉 are, respectively, superficial gas and liquid velocities. The local flow regime has been classified into four categories: bubbly, cap-slug, churn-turbulent and annular flows. In order to study the radial and axial development of flow regime the measurements have been performed at five radial locations. The three axial positions correspond to z/D_H = 52, 149 and 230, where z represents the axial position. The flow regime indicator has been chosen as some statistical parameters of local bubble chord length distributions and self-organized neural networks have been used as mapping system. This information has been also used to compare the results given by the existing flow regime transition models. The local flow regime is characterized basically by the void fraction and bubble chord length. The radial development of flow regime shows partial and complete local flow regime combinations. The radial development is controlled by axial location and superficial liquid velocity. The radial flow regime transition is always initiated in the center of the flow channel and it is propagated towards the channel boundaries. The axial development of flow regime is observed in all the flow maps and it is governed by superficial liquid velocity and radial location. The prediction results of the models are compared for each flow regime transition.     

Heat transfer and fluid dynamics of air–water two-phase flow in micro-channels

Heat transfer, pressure drop, and void fraction were simultaneously measured for upward heated air–water non-boiling two-phase flow in 0.51 mm ID tube to investigate thermo–hydro dynamic characteristics of two-phase flow in micro-channels. At low liquid superficial velocity j_l frictional pressure drop agreed with Mishima–Hibiki’s correlation, whereas agreed with Chisholm–Laird’s correlation at relatively high j_l. Void fraction was lower than the homogeneous model and conventional empirical correlations. To interpret the decrease of void fraction with decrease of tube diameter, a relation among the void fraction, pressure gradient and tube diameter was derived. Heat transfer coefficient fairly agreed with the data for 1.03 and 2.01 mm ID tubes when j_l was relatively high. But it became lower than that for larger diameter tubes when j_l was low. Analogy between heat transfer and frictional pressure drop was proved to hold roughly for the two-phase flow in micro-channel. But satisfactory relation was not obtained under the condition of low liquid superficial velocity.     

Frictional pressure drop during vapour–liquid flow in minichannels: Modelling and experimental evaluation

Condensation in minichannels is widely used in air-cooled condensers for the automotive and air-conditioning industry, in heat pipes and other applications for system thermal control. The knowledge of pressure drops in such small channels is important in order to optimize heat transfer surfaces. This paper presents a model for calculation of the frictional pressure gradient during condensation or adiabatic liquid–gas flow inside minichannels with different surface roughness. In order to account for the effects of surface roughness, new experimental frictional pressure gradient data associated to single-phase flow and adiabatic two-phase flow of R134a inside a single horizontal mini tube with rough wall has been used in the modelling. It is a Friedel (1979) [Friedel, L., 1979. Improved friction pressure drop correlations for horizontal and vertical two-phase pipe flow. In: Proceedings of the European Two-Phase Flow Group Meeting, Ispra, Paper E2] based model and it takes into account mass velocity, vapor quality, fluid properties, reduced pressure, tube diameter, entrainment ratio and surface roughness. With respect to the flow pattern prediction capability, it has been built for shear dominated flow regimes inside pipes, thus, annular, annular-mist and mist flow are here predicted. However, the suggested procedure is extended to the intermittent flow in minichannels and it is also applied with success to horizontal macro tubes.     

Characterization and prediction of two-phase flow regimes in miniature tubes

Visual observations of two-phase regimes for R134a and R245fa flowing in 0.509 mm and 0.790 mm horizontal tubes are documented and compared to the predictions of the analytical flow regime models available in the literature. Annular flow was found to dominate the behavior of these two miniature channels, with a significant Slug flow regime at intermediate qualities. Despite the horizontal orientation of these tubes, there were no observations of Stratified flow and a very limited region of Bubble flow. A comparison of the more than 2200 flow regime observations to the predictions of the Taitel–Dukler flow regime methodology revealed that 67% of the empirically observed flow pattern data were correctly identified. The Ullmann–Brauner model, based on an air–water database, correctly predicted the appropriate flow regime for 81% of the reported data. Proposed modifications in the Bubble-to-Slug and Slug-to-Annular transition criteria, respectively, were shown to provide a modest further improvement in the overall predictability to 90% of the observed data for the two refrigerants studied.     

Liquid film circumferential asymmetry prediction in horizontal annular two-phase flow

This study considers the prediction of the degree of asymmetry in the circumferential distribution of the liquid film in the tube cross section of horizontal annular gas–liquid two-phase flow, endemic of the lower region of this flow regime near the stratified-wavy flow transition boundary. Focusing on disturbance waves as the predominant mechanism for transporting the liquid in the annular film from the bottom to the top of the tube to counterbalance the draining effect of gravity, a new prediction method for the degree of asymmetry in the annular liquid film is proposed that outperforms existing correlations. Flow pattern maps for horizontal gas–liquid two-phase flow of frequent use in the design of evaporators and condensers can thus be explicitly updated to account for both symmetric and asymmetric annular flows. The underlying experimental database contains 184 measured liquid film circumferential profiles, corresponding to 1276 local liquid film thickness measurements collected from 15 different literature studies for tube diameters from 8.15 mm to 95.3 mm.     

Drop size measurements for annular two-phase flow in a 20 mm diameter vertical tube

As part of a study on the effect of tube diameter on the mean drop size and liquid film flow rate in annular two-phase flow, data was obtained for the vertical upflow of an air-water system in a 20 mm internal diameter tube, held at a pressure of 1.5 bar and ambient temperature. This complements data taken in earlier experiments on 10 and 32 mm tubes. Increases in the superficial gas velocity caused reductions in the mean drop size whilst increasing the liquid mass flux in all but the lowest gas velocity case, caused the drop size to rise. Comparisons were made between the current drop size data and that from a 10 mm and 32 mm internal diameter tube, for similar conditions of temperature and pressure. The current drop size measurements, which fall between those from earlier work, confirm the dependence of drop size on tube diameter. The performance of several drop size correlations have been tested. Because the correlations do not account for the influence of tube diameter, they fail to predict the drop size data accurately. The influence of gas and liquid flow rate on the measured film flow rate show trends similar to those seen in data from the 10 mm and 32 mm diameter tubes. Models, to calculate the entrained liquid mass flux were tested; good predictions were given.     

Flow boiling heat transfer in a vertical spirally internally ribbed tube

 Experiments of flow boiling heat transfer and two-phase flow frictional pressure drop in a spirally internally ribbed tube (φ22×5.5 mm) and a smooth tube (φ19×2 mm) were conducted, respectively, under the condition of 6×10⁵ Pa (absolute atmosphere pressure). The available heated length of the test sections was 2500 mm. The mass fluxes were selected, respectively, at 410, 610 and 810 kg/m² s. The maximum heat flux was controlled according to exit quality, which was no more than 0.3 in each test run. The experimental results in the spirally internally ribbed tube were compared with that in the smooth tube. It shows that flow boiling heat transfer coefficients in the spirally internally ribbed tube are 1.4–2 times that in the smooth tube, and the flow boiling heat transfer under the condition of smaller temperature differences can be achieved in the spirally internally ribbed tube. Also, the two-phase flow frictional pressure drop in the spirally internally ribbed tube increases a factor of 1.6–2 as compared with that in the smooth tube. The effects of mass flux and pressure on the flow boiling heat transfer were presented. The effect of diameters on flow boiling heat transfer in smooth tubes was analyzed. Based on the fits of the experimental data, correlations of flow boiling heat transfer coefficient and two-phase flow frictional factor were proposed, respectively. The mechanisms of enhanced flow boiling heat transfer in the spirally internally ribbed tube were analyzed. Received on 1 December 1999     

Critical friction factor modeling of horizontal annular base film thickness

Measurements of liquid base film thickness distribution have been obtained for 206 horizontal annular two-phase (air–water) flow conditions in 8.8 mm, 15.1 mm, and 26.3 mm ID tubes. It is found that the trends in base film thickness measurement do not match trends in the literature for average film thickness, which considers waves and base film together. An iterative critical friction factor model is used to model circumferentially-averaged base film thickness; an explicit, empirical correlation is also provided. Asymmetry is well-correlated by a modified Froude number based on the correlated base film thickness and the gas mass flux. The iterative model is also extended to estimate the critical film flow rate.     

Multiphase drag reduction: Effect of eliminating slugs

Two-phase pressure drop measurements were taken for air/water mixtures in a 0.052-m diameter horizontal pipe with special focus on the superficial liquid velocity range of 0.03–1.2 m/s at superficial gas velocities of 3.8, 5.2, and 6.6 m/s. It was found that the addition of 400 ppm of sodium dodecyl sulfate (SDS) to the water reduced the pressure drop by 25–40% when compared to equal flow rates without SDS. The pressure drop reduction occurred where the SDS eliminated the occurrence of the intermittent flow present with water. It was also found that the same concentration of SDS had virtually no effect on single phase liquid pressure drop. The pressure drop reduction appears to be due solely to the suppression of intermittent flow patterns.     

Measurement of the liquid film thickness in micro tube slug flow

Slug flow is one of the representative flow regimes of two-phase flow in micro tubes. It is well known that the thin liquid film formed between the tube wall and the vapor bubble plays an important role in micro tube heat transfer. In the present study, experiments are carried out to clarify the effects of parameters that affect the formation of the thin liquid film in micro tube two-phase flow. Laser focus displacement meter is used to measure the thickness of the thin liquid film. Air, ethanol, water and FC-40 are used as working fluids. Circular tubes with five different diameters, D = 0.3, 0.5, 0.7, 1.0 and 1.3 mm, are used. It is confirmed that the liquid film thickness is determined only by capillary number and the effect of inertia force is negligible at small capillary numbers. However, the effect of inertia force cannot be neglected as capillary number increases. At relatively high capillary numbers, liquid film thickness takes a minimum value against Reynolds number. The effects of bubble length, liquid slug length and gravity on the liquid film thickness are also investigated. Experimental correlation for the initial liquid film thickness based on capillary number, Reynolds number and Weber number is proposed.     

Experimental investigation of flow boiling characteristics in a cross-linked microchannel heat sink

This paper experimentally investigates flow boiling characteristics in a cross-linked microchannel heat sink at low mass fluxes and high heat fluxes. The heat sink consists of 45 straight microchannels each with a hydraulic diameter of 248 μm and heated length of 16 mm. Three cross-links, of width 500 μm, are introduced in the present microchannel heat sink to achieve better temperature uniformity and to avoid flow mal-distribution. Flow visualization, flow instability, two-phase pressure drop, and two-phase heat transfer measurements are conducted using the dielectric coolant FC-72 over a range of heat flux from 7.2 to 104.2 kW/m², mass flux from 99 to 290 kg/m² s, and exit quality from 0.01 to 0.71. Thermochromic liquid crystals are used in the present study as full-field surface temperature sensors to map the temperature distribution on the heat sink surface. Flow visualization studies indicate that the observed flow regime is primarily slug. Visual observations of flow patterns in the cross-links demonstrate that bubbles nucleate and grow rapidly on the surface of the cross-links and in the tangential direction at the microchannels’ entrance due to the effect of circulations generated in those regions. The two-phase pressure drop strongly increases with the exit quality, at x_e,o < 0.3, and the two-phase frictional pressure drop increases by a factor of 1.6–2 compared to the straight microchannel heat sink. The flow boiling heat transfer coefficient increases with increasing exit quality at a constant mass flux, which is caused by the dominance of the nucleation boiling mechanism in the cross-link region.