Refrigerant distribution in a parallel flow heat exchanger having vertical headers and heated horizontal tubes

Refrigerant R-410a flow distribution is experimentally studied in a test section simulating a parallel flow heat exchanger having vertical headers with two pass configuration. Tubes are heated to yield a test section outlet superheat of 5 °C with inlet quality of 0.3. Mass flux is varied from 50 kg/m² s to 70 kg/m² s. Effects of inlet and outlet locations are investigated in a search for an optimum configuration. Results show that, significant liquid flows through bottom channels, and less liquid is supplied to top channels. As for the inlet location, better flow distribution (pressure drop as well) is obtained for top inlet as compared with middle inlet. As for the outlet location, top or bottom outlet is better than middle outlet. Correlations are developed for the fraction of liquid or gas taken off by downstream channel as a function of header gas Reynolds number at immediate upstream. The correlations may be used to predict the liquid or gas distribution in a parallel flow heat exchanger having vertical headers. A novel thermal performance evaluation method, which accounts for tube-side flow mal-distribution is proposed.     

A semi-empirical model of two-phase flow of refrigerant-134a through short tube orifices

Measurements were conducted on Refrigerant-134a flowing through short tube orifices with length-to-diameter (L/D) ratios ranging from 5 to 20. Both two-phase and subcooled liquid flow conditions entering the short tube were examined for upstream pressures ranging from 896 to 1448 kPa and for qualities as high as 10% and subcoolings as high as 13.9°C. Data were analyzed as a function of the main operating variables and tube geometry. Semi-empirical models for both single- and two-phase flow at the inlet of the short tubes were developed to predict the mass flow of Refrigerant-134a through short tube orifices.

Choked flow conditions for Refrigerant-134a were typically established when downstream pressures were reduced below the saturation pressure corresponding to the inlet temperature. The flow rate strongly depended on the upstream pressure and upstream subcooling/quality. The mass flow also depended on cross-sectional area and short tube length. The mass flow model utilized a modified orifice equation that formulated the mass flow as a function of normalized operating variables and short tube geometry. For a two-phase flow entering the short tube, the modified orifice equation was corrected using a theoretically derived expression that related the liquid portion of the mass flow under two-phase conditions to a flow that would occur if the flow were a single-phase liquid. It was found that for sharp-edged short tubes with single- and two-phase flow, approximately 95% of the measured data and model's prediction were within ±15% of each other.     

Equal quality distribution of gas–liquid two-phase flow by partial separation method

This paper proposes a new method for equal quality distribution of gas–liquid two-phase flow by partial separate-phase distribution with a dual-header distributor. The upper and liquid (lower) headers are interconnected with five vertical downward arms. A gas–liquid two-phase mixture enters the distributor from the upper header where most of the liquid of the mixture is removed through the downward arms into the liquid header. Hence, firstly, the remaining gas-rich fluid can be uniformly distributed into the outlet branches, and then secondly, the liquid collected in the liquid header can be uniformly re-distributed into the individual outlet branches. Because both distribution processes are conducted in the condition of single or near single-phase flow, mal-distribution of the two-phase flow is essentially eliminated, and a satisfactory equal quality distribution of gas–liquid two-phase flow is reached. Experiments were conducted in an air–water two-phase flow test loop. The inner diameter of the inlet pipe was 60 mm, the superficial velocity ranges of gas and liquid were 3–32 m/s and 0.02–0.17 m/s respectively, and the quality ranged from 0.02 to 0.44. The flow pattern in the inlet pipe included stratified flow, wavy stratified, slug flow, and annular flow. The experimental results showed that this new method could significantly improve the distribution performance of the two-phase flow. The maximum quality deviation between each outlet branch and the inlet pipe is less than ±1% under the conditions of stratified, wavy stratified and slug flows in the upper header, and less than ±5% in annular flow.     

Experimental study of in-tube cooling heat transfer and pressure drop characteristics of R134a at supercritical pressures

The in-tube cooling flow and heat transfer characteristics of R134a at supercritical pressures are measured experimentally for various pressures and mass fluxes in a horizontal tube. The tube is made of stainless steel with an inner diameter of 4.01 mm. Experiments are conducted for mass fluxes from 70 kg/m² s to 405 kg/m² s and pressures from 4.5 MPa to 5.5 MPa. The inlet refrigerant temperature is from 80 °C to 140 °C. The results show that the refrigerant temperature, the mass flux and the pressure all significantly affect the flow and heat transfer characteristics of R134a at supercritical pressures. The experimentally measured frictional pressure drop and heat transfer coefficient are compared with predicted results from several existing correlations. The comparisons show that the predicted frictional pressure drop using Petrov and Popov’s correlation accounting for the density and viscosity variations agree well with the measured data. Gnielinski’s correlation for the heat transfer coefficient agrees best with the measured data with deviations not exceeding 25%, while correlations based on supercritical CO₂ heat transfer data overcorrect for the influence of the thermophysical property variations resulting in larger deviations. A new empirical correlation is developed based on the measured results by modifying Gnielinski’s equation with thermophysical property terms including both the property variations from the inlet to the outlet of the entire test section and from the bulk to the wall. Most of the experimental data is predicted by the new correlation within a range of 15%.     

Two-phase flow instabilities in a silicon microchannels heat sink

Two-phase flow instabilities are highly undesirable in microchannels-based heat sinks as they can lead to temperature oscillations with high amplitudes, premature critical heat flux and mechanical vibrations. This work is an experimental study of boiling instabilities in a microchannel silicon heat sink with 40 parallel rectangular microchannels, having a length of 15 mm and a hydraulic diameter of 194 μm. A series of experiments have been carried out to investigate pressure and temperature oscillations during the flow boiling instabilities under uniform heating, using water as a cooling liquid. Thin nickel film thermometers, integrated on the back side of a heat sink with microchannels, were used in order to obtain a better insight related to temperature fluctuations caused by two-phase flow instabilities. Flow regime maps are presented for two inlet water temperatures, showing stable and unstable flow regimes. It was observed that boiling leads to asymmetrical flow distribution within microchannels that result in high temperature non-uniformity and the simultaneously existence of different flow regimes along the transverse direction. Two types of two-phase flow instabilities with appreciable pressure and temperature fluctuations were observed, that depended on the heat to mass flux ratio and inlet water temperature. These were high amplitude/low frequency and low amplitude/high frequency instabilities. High speed camera imaging, performed simultaneously with pressure and temperature measurements, showed that inlet/outlet pressure and the temperature fluctuations existed due to alternation between liquid/two-phase/vapour flows. It was also determined that the inlet water subcooling condition affects the magnitudes of the temperature oscillations in two-phase flow instabilities and flow distribution within the microchannels.     

Experimental investigation of two-phase flow splitting in an equal-sided impacting tee junction with inclined outlets

Phase-distribution data have been generated for two-phase (air-water) flow splitting at an impacting tee junction with a horizontal inlet and inclined outlets. This investigation also considered the possibility of full separation at the junction and the effect of the outlet angle of inclination on partial separation at various inlet conditions. A flow loop with the ability to incline the outlets from horizontal to vertical was constructed. The operating conditions were as follows: test section inside diameter (D) of 13.5 mm, nominal junction pressure (P_s) of 200 kPa (abs), near ambient temperature (T_s), inlet superficial gas velocities (J_G1) ranging from 2.0 to 40 m/s, inlet superficial liquid velocities (J_L1) ranging from 0.01 to 0.18 m/s, inlet qualities (x₁) ranging from 0.1 to 0.9, mass split ratios (W₃/W₁) from 0 to 1.0, and inlet flow regimes of stratified, wavy, and annular. The data reveal that the degree of maldistribution of the phases depended on the inlet conditions, the mass split ratio at the junction, and the inclination angle of the outlets.     

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.     

The effect of pipe diameter on the structure of gas/liquid flow in vertical pipes

Experimental work on two-phase vertical upward flow was carried out using a 19 mm internal diameter, 7 m long pipe and studying the time series of cross-sectional average void fractions and pressure gradient which were obtained simultaneously. With the aid of a bank of published data in which the pipe diameter is the range from 0.5 to 70 mm, the effect of pipe diameter on flow characteristics of two-phase flow is investigated from various aspects. Particularly, the work focuses on the periodic structures of two-phase flow. Average film thicknesses and the gas flow rate where slug/churn and churn/annular flow transitions occur all increase as the diameter of the pipe becomes larger. On the other hand, the pressure gradients, the frequencies of the periodic structures and the velocities of disturbance waves decrease. The velocity of disturbance waves has been used to test the model of Pearce (1979). It is found that the suggested value of Pearce coefficient 0.8 is reasonable for lower liquid flow rates but becomes insufficient for higher liquid flow rates.     

The onset of gas entrainment from a flowing stratified gas–liquid regime in dual discharging branches: Part II: Critical conditions at low to moderate branch Froude numbers

This is the second of a two part investigation. Experiments were performed in a 50.8 mm diameter horizontal pipe with three 6.35 mm diameter branches located at the test section mid-span. The inlet length was 1.8 m, and three branch orientations were tested at 0° (side), 45° (inclined), and 90° (bottom) from horizontal. Water and air, operating at 206 kPa, were used and both fluids flowed co-currently within the inlet in the smooth-stratified regime. The inlet superficial velocity of the liquid phase ranged between 0.04 and 0.15 m/s while in the gas phase values of 0.3, 0.4, and 1 m/s were tested. Three different dual discharge combinations were tested and included side-inclined, side-bottom, and inclined-bottom. The tested branch flow Froude numbers were limited between low to moderate values which ranged between 1 and 23. Extensive experimental data are reported for the critical conditions at the onset of gas entrainment during dual discharge. A novel map was developed for the inclined-bottom branch configuration showing the relationship between the inlet superficial liquid velocity and branch Froude numbers. This map was used to quantify the three observed modes of gas entrainment during dual discharge. These modes were classified as onset of gas entrainment in the inclined branch only, in the bottom branch only, or both the inclined and bottom branches simultaneously. The critical height at the onset of gas entrainment results are compared to published models and data sets and poor agreement was found with studies conducted in stratified gas–liquid reservoirs.     

Experimental study on the heat transfer coefficient of water flow boiling in mini/microchannels

The heat transfer coefficients of the evaporative water flow in mini/microchannels are studied experimentally to explore the novel heat dissipation for high power electronics. Two sets of parallel channels which are 61 channels with hydraulic diameter of 0.293 mm and 20 channels with hydraulic diameter of 1.2 mm are investigated respectively. The inlet and outlet temperatures of fluids, and the temperatures beneath the channels are measured to calculate the heat dissipation of the evaporative water in channels. The experiments are carried out with the mass flow rates range from 11.09 kg/(m² s) to 44.36 kg/(m² s) for minichannels and 49.59 kg/(m² s) to 198.37 kg/(m² s) for microchannels. The effective heat flux range from 5 W/cm² to 50 W/cm², and the resulted outlet vapor qualities range from 0 to 0.8. The relations of the heat transfer coefficient with heat flux and vapor quality are analyzed according to the results. The experimental heat transfer coefficients are compared with the prediction of latest developed correlations. A new correlation takes the effect of Bond number is proposed, and be verified that it is effective to predict the heat transfer coefficient of both minichannels and microchannels in a large range of vapor qualities.     

Experimental study on axial development of liquid film in vertical upward annular two-phase flow

Accurate measurements of the interfacial wave structure of upward annular two-phase flow in a vertical pipe were performed using a laser focus displacement meter (LFD). The purpose of this study was to clarify the effectiveness of the LFD for obtaining detailed information on the interfacial displacement of a liquid film in annular two-phase flow and to investigate the effect of axial distance from the air–water inlet on the phenomena. Adiabatic upward annular air–water flow experiments were conducted using a 3 m long, 11 mm ID pipe. Measurements of interfacial waves were conducted at 21 axial locations, spaced 110 mm apart in the pipe. The axial distances from the inlet (z) normalized by the pipe diameter (D) varied over z/D = 50–250. Data were collected for predetermined gas and liquid flow conditions and for Reynolds numbers ranging from Re_G = 31,800 to 98,300 for the gas phase and Re_L = 1050 to 9430 for the liquid phase. Using the LFD, we obtained such local properties as the minimum thickness, maximum thickness, and passing frequency of the waves. The maximum film thickness and passing frequency of disturbance waves decreased gradually, with some oscillations, as flow developed. The flow development, i.e., decreasing film thickness and passing frequency, persisted until the end of the pipe, which means that the flow might never reach the fully developed state. The minimum film thickness decreased with flow development and with increasing gas flow rate. These results are discussed, taking into account the buffer layer calculated from Karman’s three-layer model. A correlation is proposed between the minimum film thickness obtained in relation to the interfacial shear stress and the Reynolds number of the liquid.     

Phase split of nitrogen/non-Newtonian fluid two-phase flow at a micro-T-junction

An experimental investigation has been undertaken to understand the phase split of nitrogen gas/non-Newtonian liquid two-phase flow passing through a 0.5 mm T-junction that oriented horizontally. Four different liquids, including water and aqueous solutions of carboxymethyl cellulose (CMC) with different mass concentrations of 0.1, 0.2 and 0.3 wt%, were employed. Rheology experiments showed that different from water, CMC solutions in this study are pseudoplastic non-Newtonian fluid whose viscosity decreases with increasing the shear rate. The inlet flow patterns were observed to be slug flow, slug–annular flow and annular flow. The fraction of liquid taken off at the side arm for nitrogen gas/non-Newtonian liquid systems is found to be higher than that for nitrogen gas/Newtonian liquid systems in all inlet flow patterns. In addition, with increasing the pseudoplasticity of the liquid phase, the side arm liquid taken off increases, but the increasing degree varies with each flow pattern. For annular flow, the increasing degree is much greater than those for slug and slug–annular flows.     

Evaluating cavitation regimes in an internal orifice at different temperatures using frequency analysis and visualization

Experiments on a water cavitating orifice were conducted to investigate the influence of pressure and temperature on flow regime transition due to cavitation. The thermal effects could be important in cases with cryogenic cavitation or hot fluid injection. The investigations were based on CCD observations and a pressure fluctuations frequency analysis.The high-speed photographic recordings were used to analyze the cavitation evolution and individuate the frequency content of the two-phase flow by processing the pixel-intensity time-series data.The cavitating structures showed different behaviors and characteristics with variations in operating conditions, as the pressure inside the orifice and the flow temperature .The flow regime map for the cavitating flow was obtained using experimental observations to analyze the occurrence of the different two-phase flow regime transitions at various operating conditions.As the pressure at the orifice inlet increased, at the same downstream pressure, cavitation inception occurred. The decrease of the cavitation number brought a significant increase in cavitation zone extension. As the pressure drop inside the orifice increased, the cavitation was characterized by an evident increase in cavitation zone length to the outlet of the orifice. With a further cavitation number decrease, the transition to jet cavitation was evident.The temperature influenced both the cavitation intensity and the cavitation number at which different two-phase flow regime transitions occurred, which tended to increase with temperature.The vapor fraction was estimated using an image processing algorithm.The frequency content given by the pressure fluctuations was analyzed and compared with the frequency spectra obtained from the visual observations. The behavior of the different cavitating flows could be correlated to the frequency spectrum of the pressure fluctuations measured upstream and downstream of the orifice. The cavitation number reduction and consequent increase in cavitating area width were related to a corresponding significant increase in the amplitude of typical frequency components. The transition to jet cavitation was characterized by a significant increase in the first peak in the frequency spectrum; weaker spectral peaks were also present at high cavitation numbers.     

Carbon dioxide flow boiling in a single microchannel - Part I: Pressure drops

Carbon dioxide two-phase flow pressure drops have been investigated in a single horizontal stainless-steel micro-tube having a 0.529 mm inner diameter. Experiments were carried out in adiabatic conditions for four saturation temperatures of −10; −5; 0; 5 °C and mass fluxes ranging from 200 to 1400 kg/m² s, for inlet qualities up to unity. Measurements have been compared to the predictions of well-known methods. The Müller-Steinhagen and Heck correlation and the Friedel correlation gave the best fit as well as the homogeneous model when the liquid viscosity is used to represent the apparent two-phase viscosity. Further, an analysis based on the homogeneous model has not shown any clear appearance of the laminar or the transition regimes in any given range of Reynolds number. The apparent viscosity of the two-phase mixture was found larger than the liquid viscosity at low vapour qualities, namely at the lowest temperatures. Hence, a new expression to determine the equivalent viscosity was suggested as a function of the reduced pressure. Lastly, the Chisholm parameter from the Lockhart-Martinelli correlation was found lower than expected and also mainly dependent on the saturation temperature.     

Experimental investigation of post-dryout heat transfer in annulus with spacers

Experimental investigations of post-dryout heat transfer in 10 × 22.1 annulus test section with spacers were carried out in the high-pressure two-phase flow loop at the Royal Institute of Technology (KTH). The test section was manufactured of Inconel 600 to withstand high temperatures. Several thermocouples were installed on tube and rod surfaces to measure the local wall temperature. Measurements were performed for mass flow rate in range from 500 to 2000 kg m⁻² s⁻¹, with inlet subcooling equal to 10 and 40 K, heat flux in a range from 480 to 1380 kW m⁻² and for the system pressure of 7 MPa. Uniform axial power distributions were applied on rod and tube walls. Using different distributions of heat flux between walls, post-dryout was achieved either on the inner or on the outer wall. The experimental results indicate a very strong influence of spacers on post-dryout heat transfer. For low mass flow rates the wall superheat was significantly reduced downstream of spacers, even though the whole distance between spacers was still under post-dryout conditions when heat flux was high enough. At high mass flow rates and under investigated range of heat flux the dryout patches were effectively quenched downstream of spacers.     

Liquid flow in a simplex swirl nozzle

Pressure-swirl nozzles are widely used in applications such as combustion, painting, air-conditioning, and fire suppression. Understanding the effects of nozzle geometry and inlet flow conditions on liquid film thickness, discharge coefficient and spray angle is very important in nozzle design. The nozzle-internal flow is two-phase with a secondary flow which makes its detailed analysis rather complex. In the current work, the flow field inside a pressure-swirl nozzle is studied theoretically. Using the integral momentum method, the growth of the boundary layer from the nozzle entry to the orifice exit is investigated and the velocity through the boundary layer and the main body of the swirling liquid is calculated. A numerical modeling and a series of experiments have also been performed to validate the theoretical results. The effect of various geometrical parameters is studied and results are compared for viscous and inviscid cases. In addition, the condition in which the centrifugal force of the swirling flow overcomes the viscous force and induces an air core is predicted. The theoretical analysis discussed in this paper provides better criteria for the design and the performance analysis of nozzles.     

Freon R141b flow boiling in silicon microchannel heat sinks: experimental investigation

This paper presents experimental investigations on Freon R141b flow boiling in rectangular microchannel heat sinks. The main aim is to provide an appropriate working fluid for microchannel flow boiling to meet the cooling demand of high power electronic devices. The microchannel heat sink used in this work contains 50 parallel channels, with a 60 × 200 (W × H) μm cross-section. The flow boiling heat transfer experiments are performed with R141b over mass velocities ranging from 400 to 980 kg/(m² s) and heat flux from 40 to 700 kW/m², and the outlet pressure satisfying the atmospheric condition. The fluid flow-rate, fluid inlet/outlet temperature, wall temperature, and pressure drop are measured. The results indicate that the mean heat transfer coefficient of R141b flow boiling in present microchannel heat sinks depends heavily on mass velocity and heat flux and can be predicted by Kandlikar’s correlation (Heat Transf Eng 25(3):86–93, 2004). The two-phase pressure drop keeps increasing as mass velocity and exit vapor quality rise.     

Choked flow mechanism of HFC-134a flowing through short-tube orifices

This paper is a continuation of the author’s previous work. New experimental data on the occurrence of choked flow phenomenon and mass flow rate of HFC-134a inside short-tube orifices under choked flow condition are presented. Short-tube orifices diameters ranging from 0.406 mm to 0.686 mm with lengths ranging from 1 mm to 3 mm which can be applied to a miniature vapour-compression refrigeration system are examined. The experimental results indicated that the occurrence of choked flow phenomena inside short-tube orifices is different from that obtained from short-tube orifice diameters of greater than 1 mm, which are typically used in air-conditioner. The beginning of choked flow is dependent on the downstream pressure, degree of subcooling, and length-to-diameter ratio. Under choked flow condition, the mass flow rate is greatly varied with the short-tube orifice dimension, but it is slightly affected by the operating conditions. A correlation of mass flow rate through short-tube orifices is proposed in terms of the dimensionless parameters. The predicted results show good agreement with experimental data with a mean deviation of 4.69%.     

Flow patterns of n-hexadecane–CO2 liquid–liquid two-phase flow in vertical pipes under high pressure

To promote a better understanding of liquid–liquid two-phase flow behavior, particularly under high pressure, flow patterns of n-hexadecane–CO₂ liquid–liquid two-phase upward flow in vertical stainless steel pipes were experimentally investigated. Observations were made in two 0.0015 m I.D. pipes of different lengths (0.068 m and 0.5 m) under high pressure varying from 10.3 to 29.6 MPa using a high pressure visualization system. The total flow rate was fixed at 2.0 × 10⁻⁶ m³/min, while the flow rate ratio (φ) varied from 0.05 to 19. Bubbly flow, plug flow, slug flow, annular flow, and near-one-phase flow regions were found in both pipes, while stratified flow was observed only in the 0.068 m pipe. Flow pattern maps were constructed in the flow rate ratio versus pressure graph, which demonstrates significant impacts of flow rate ratio, pipe length, and pressure on flow patterns. These impacts are discussed in detail. To the authors’ best knowledge, this work is the first attempt to observe complex liquid–liquid two-phase flow behavior with flow pattern transitions under high pressure, and contributes to a better understanding of liquid–liquid two-phase flow behavior.