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.     

On the use of the stratified momentum balance for the deduction of shear stress in horizontal gas–liquid pipe flow

The use of the stratified flow momentum balance for the deduction of interfacial and liquid wall shear stresses from experimental measurements is examined. A systematic error analysis is applied to the governing equations using the principle of maximum uncertainty. A series of air–water experiments were conducted in 50 and 80 mm diameter pipes, in which gas pressure drop, liquid height and gas wall shear stress were measured. A framework for the correlation of the deduced shear stresses is proposed from the experimental measurements. The uncertainty analysis is used to show that the definition of mean liquid height does not significantly influence the overall results. The development of empirical equations based on such methods may lead to total uncertainties of up to 40%, irrespective of accuracy of the experimental data or the appropriateness of the correlating technique. Comparisons with state-of-the-art correlations for the liquid wall and interfacial friction factor data showed even larger discrepancies between measurement and prediction.     

On the use of the stratified momentum balance for the deduction of shear stress in horizontal gas–liquid pipe flow

The use of the stratified flow momentum balance for the deduction of interfacial and liquid wall shear stresses from experimental measurements is examined. A systematic error analysis is applied to the governing equations using the principle of maximum uncertainty. A series of air–water experiments were conducted in 50 and 80 mm diameter pipes, in which gas pressure drop, liquid height and gas wall shear stress were measured. A framework for the correlation of the deduced shear stresses is proposed from the experimental measurements. The uncertainty analysis is used to show that the definition of mean liquid height does not significantly influence the overall results. The development of empirical equations based on such methods may lead to total uncertainties of up to 40%, irrespective of accuracy of the experimental data or the appropriateness of the correlating technique. Comparisons with state-of-the-art correlations for the liquid wall and interfacial friction factor data showed even larger discrepancies between measurement and prediction.     

A separated flow model for predicting two-phase pressure drop and evaporative heat transfer for vertical annular flow

A separated flow model has been developed that is applicable to vertical annular two-phase flow in the purely convective heat transfer regime. Conservation of mass, momentum, and energy are used to solve for the liquid film thickness, pressure drop, and heat transfer coefficient. Closure relationships are specified for the interfacial friction factor, liquid film eddy-viscosity, turbulent Prandtl number, and entrainment rate. Although separated flow models have been reported previously, their use has been limited, because they were tested over a limited range of flow and thermal conditions. The unique feature of this model is that it has been tested and calibrated against a vast array of two-phase pressure drop and heat transfer data, which include upflow, downflow, and microgravity flow conditions. The agreements between the measured and predicted pressure drops and heat transfer coefficients are, on average, better or comparable to the most reliable empirical correlations. This separated flow model is demonstrated to be a reliable and practical predictive tool for computing two-phase pressure drop and heat transfer rates. All of the datasets have been obtained from the open literature.     

Heat transfer and interfacial drag in countercurrent steam-water stratified flow

Local condensation heat transfer coefficients and interfacial shear stresses have been measured for countercurrent stratified flow of steam and subcooled water in rectangular channels over a wide range of inclination angles (4–87°) at two aspect ratios. Dimensionless correlations for the interfacial friction factor have been developed that show that it is a function of the liquid Reynolds number only. Empirical correlations of the heat transfer coefficient, based upon the bulk flow properties, have also been set up for the whole body of data encompassing the different inclination angles and aspect ratios. These indicate that the Froude number as a dimensionless gas velocity is a better correlating parameter than the gas Reynolds number. As an alternative approach, a simple dimensionless relationship for the beat transfer coefficient was obtained by analogy between heat and momentum transfer through the interface. Finally, a turbulence-centered model has been modified by using measured interfacial parameters for the turbulent velocity and length scales, resulting in good agreement with the data.     

Positive frictional pressure gradient in vertical gas-high viscosity oil slug flow

The present study describes the wall shear stress and the falling liquid film behavior in upward vertical slug flow of air and high viscosity oil. The frictional pressure gradient is directly related to the wall shear stress, and it is usually negative (opposite to the overall flow direction). However, in vertical slug flow, the average total wall shear stress of a slug unit may be negative (in the same direction of the overall flow), resulting in a positive frictional pressure gradient. However, this does not mean, by any way, generation of additional energy or violation of the second law of thermodynamics.The positive frictional pressure gradient phenomenon, reasons and required conditions were explained in this paper. A simplified model was developed and validated against recent experimental data of air-high viscosity oil slug flow in a 50.8 mm ID vertical pipe. The oil viscosity was in the range of 127 mPa s to 580 mPa s. Positive frictional pressure gradient appears when the liquid film wall shear stress supersede the wall shear stress in the slug body. The rate of increase of both wall shear stresses (with respect to the mixture Reynolds number) depend, not only, on the mixture Reynolds number but also, highly, on the liquid viscosity.     

Condensation pressure drop of HFC-134a and R-404A in a smooth and micro-fin U-tube

The frictional pressure drop during condensation of HFC-134a and R-404A in a smooth (8.56 mm ID) and micro-fin U-tubes (8.96 mm ID) are experimentally investigated. Different from previous studies, the present experiments are performed for various condensing temperatures. The test runs are done at average saturated condensing temperatures ranging from 35 °C to 60 °C. The mass fluxes are between 90 and 800 kg/m²s. The experimental results indicate that the average frictional pressure drop increases with mass flux but decreases with increasing condensing temperature for both smooth and micro-fin-tubes. The average frictional pressure drops of HFC-134a and R-404A for the micro-fin-tubes were 1-1.7 and 1-2.1 times larger than that in smooth tube respectively. New correlations based on the data gathered during the experimentation for predicting frictional pressure drop are proposed for wide range of operating conditions.     

A Semi-empirical Correlation for Pressure Drop in Packed Beds of Spherical Particles

The effect of a confining wall on the pressure drop of fluid flow through packed beds of spherical particles with small bed-to-particle diameter ratios was investigated to develop an improved pressure drop correlation. The dependency of pressure loss on both wall friction and increased porosity near the wall was accounted for by using a theoretical approach. A semi-empirical model was created based upon the capillary-orifice model, which included a wall correction factor for the inertial pressure loss. In this model, packed beds were treated as a bundle of capillary tubes whose orifice diameter in the core region was different from that of the wall region. Using this model, a new pressure drop correlation was obtained, based on the Ergun equation and applicable for a wide range of Reynolds numbers (10⁻²–10³). The proposed correlation was compared with previous correlations, as well as with experimental data. This correlation showed close agreement with the experimental data for both low- and high-Reynolds number regimes and for a wide range of bed-to-particle diameter ratios. The ratio of the pressure drop in finite packing to that in homogeneous packing was then calculated. This ratio clearly shows how the wall effect depends on the Reynolds number and the bed-to-particle diameter ratio.     

Frictional contact problem of a rigid stamp and an elastic layer bonded to a homogeneous substrate

In this study, the frictional contact problem for a layer bonded to a homogeneous substrate is considered according to the theory of elasticity. The layer is indented by a rigid cylindrical stamp which is subjected to concentrated normal and tangential forces. The friction between the layer and the stamp is taken into account. The problem is reduced to a singular integral equation of the second kind in which the contact pressure function and the contact area are the unknown by using integral transform technique and the boundary conditions of the problem. The singular integral equation is solved numerically using both the Jacobi polynomials and the Gauss?CJacobi integration formula, considering equilibrium and consistency conditions. Numerical results for the contact pressures, the contact areas, the normal stresses, and the shear stresses are given, for both the frictional and the frictionless contacts.     

Experimental two-phase pressure gradients during evaporation of pure and mixed refrigerants in a smooth horizontal tube. Comparison with correlations

The paper reports the results of an experimental study on pressure drop during horizontal flow boiling of refrigerants R22, R507, R404A, R134a, R407C and R410A. The test section is a smooth, horizontal, stainless steel tube (6 mm I.D., 6 m length) uniformly heated by Joule effect. The experimental tests are carried out at an almost constant evaporating pressure of 7.0 bar varying the mass flow rate in the range 280–1,080 kg/m² s. The experimental comparison clearly shown that the pressure drop of R22 is significantly higher as compared to all the other fluids. The results are compared against well-known pressure drop prediction methods. The available correlations can be used for both pure fluids and mixtures with no corrective factors, provided the mixture properties are evaluated at local compositions. The Chawla friction correlation is the best-fitting of our experimental data in combination with the heterogeneous momentum pressure drop model on the basis of the Rouhani-Axelsson void fraction correlation.     

Formation of heterogeneous spatial structures in a boundary lubrication layer during friction

This paper presents a synergetic model describing the boundary friction of two atomically smooth solid surfaces separated by an ultrathin lubricant layer. The model is constructed using the Lorenz system of equations, which is parameterized by shear stresses, shear strains, and the lubricant temperature. Given the spatial inhomogeneity of these parameters, it is shown that a structure with two types of domains is formed during friction on the contact plane. Time dependences of the fractal dimensions of the domain distributions over the contact plane are calculated, and it is shown that there exists a time when the fractal dimensions take minimum values. During the evolution, the system tends to a homogeneous state in which the shear stresses over entire contact area have a constant value which determines the relative velocity of motion of the friction blocks.     

Pressure drop during forced convection boiling of binary refrigerant mixtures

An experimental investigation was carried out in an electrically heated horizontal tube to measure pressure drop for various flow rates and heat fluxes during forced convection boiling of pure refrigerant 12 and four compositions of refrigerants 13 and 12 mixtures. The Martinelli-Nelson correlation, using the properties of the flowing refrigerant mixture, could not predict satisfactorily the pressure drop data. Total, as well as frictional pressure drops were found to be function of concentration. Two separate models each for total, as well as frictional pressure drop were developed for predicting the corresponding pressure drop. In each case, the maximum per cent deviation between predicted and measured pressure drop was within $\text{± 30\%}$.     

Zur Kondensation an der Wand dampfdurchströmter Kanäle mit veränderlichem Querschnitt

The flow of pure vapor in channels with variable cross section and cooled walls is considered. The balances for mass, energy and momentum and the transport of heat across the film of condensate are dealt by a finite difference method. Selected examples show that convergent channels improve condensation compared with channels of constant cross section. Excessive temperature drop by acceleration, however, must be avoided. Adversed pressure gradient may cause separation of the condensate film. The influence of the following parameters is discussed: gravity, increased friction, entrainment of condensat, cocurrent and countercurrent flow of the cooling medium and finite resistance of heat of channel wall. The shape of velocity profiles of the condensate is shown as a function of the pressure gradient.     

A reassessment of the wall effect of non-newtonian flow of polymer solutions

An apparatus for checking slip interpretation of flow anomalies in the laminar capillary flow of macromolecular solutions is described. It consists of a two-dimensional flow channel, having a uniform width of 1.5 inch and an alternative, convergent taper that is adjustable. Dilute aqueous solutions of the polymers Carbopol, Natrosol, and Polyox are recirculated in steady laminar flow from a large reservoir. Velocities, pressures, and wall shear stresses are measured. Local velocities are obtained by the local injection of conductive tracer fluid, whose passage is sensed by sets of electrodes stationed along the flow. Wall shear stresses are measured on a small, freely displaceable, traction surface flush with the channel wall. The tests cover concentrations of Carbopol of 0.1% to 0.4%, Natrosol of 0.5% to 1%, and Polyox of 0.5% to 1%. Approximate viscosities range from about 10 to 1000 cP. Wall shear rates up to 1000 s^–1 are attained.The results are in good agreement with the established viscometric properties of the tested materials. Actual shear stresses agree with those calculated from pressure drops, and velocities exhibit no detectable anomaly near the wall. Any velocity anomaly in the experiment would have to be less than 3% of the mean flow velocity.An order of magnitude analysis, based on particulate behavior, is made in an attempt to delineate an underlying mechanism.     

倾斜吹吸控制下湍流边界层减阻的直接数值模拟

雷诺切应力是壁湍流高摩擦阻力的重要来源, 有理论认为可以通过壁面生成负雷诺应力(数值上为正)的方式来削弱湍流流场中雷诺应力的分布, 以此获得流动减阻. 而通过对雷诺平均运动方程的法向二次积分, 可以发现壁面生成正雷诺应力(数值上为负)对壁面摩擦阻力系数才有负贡献. 文中在湍流边界层流动的控制区域下边界设置一系列倾斜狭缝, 利用该装置通过周期性吹吸的方法产生壁面生成正(负)雷诺应力, 并采用直接数值模拟方法考察和验证上文提到的减阻理论. 文中采用的湍流边界层流动模型, 其流动雷诺数(基于外流速度及动量损失厚度)从300 发展到860. 文中通过多组数值模拟算例, 考察了射流强度和频率对壁面摩擦阻力系数的影响, 并对比了壁面生成正或负雷诺应力对流动的影响. 研究表明, 壁面生成正雷诺应力控制的减阻率能达到3.26, 而壁面生成负雷诺应力控制的减阻效果较壁面生成正雷诺应力控制的要差; 壁面生成的正雷诺应力对壁面摩擦阻力有负贡献, 而壁面生成的负雷诺应力对壁面摩擦阻力有正贡献; 通过考察控制的收支比, 发现控制方案不能获得能量净收益.      

Effect of diameter on two-phase pressure drop in narrow tubes

The effect of tube diameter on two-phase frictional pressure drop was investigated in circular tubes with inner diameters of 0.6, 1.2, 1.7, 2.6 and 3.4 mm using air and water. The gas and liquid superficial velocity ranges were 0.01-50 m/s and 0.01-3 m/s, respectively. The gas and liquid flow rates were measured and the two-phase flow pattern images were recorded using high-speed CMOS camera. Unique flow patterns were observed for smaller tube diameters. Pressure drop was measured and compared with various existing models such as homogeneous model and Lockhart-Martinelli model. It appears that the dominant effect of surface tension shrinking the flow stratification in the annular regime is important. It was found that existing models are inadequate in predicting the pressure drop for all the flow regimes visualized. Based on the analysis of present experimental frictional pressure drop data a correlation is proposed for predicting Chisholm parameter “C” in slug annular flow pattern. For all other flow regimes Chisholm’s original correlation appears to be adequate except the bubbly flow regime where homogeneous model works well. The modification results in overall mean deviation of pressure drop within 25% for all tube diameters considered. This approach of flow regime based modification of liquid gas interaction parameter appears to be the key to pressure drop prediction in narrow tubes.     

Three-dimensional laminar flow and heat transfer in the entrance region of trapezoidal ducts

The laminar convective flow and heat transfer in a duct with a trapezoidal cross-sectional area are studied numerically. The governing equations are solved numerically by a finite volume formulation in complex three-dimensional geometries using co-located variables and Cartesian velocity components. Details of the numerical method are presented. The accuracy of the method was also established by comparing the calculated results with the analytical and numerical results available in the open literature. The Nusselt numbers are obtained for the boundary condition of a uniform wall temperature whereas the friction factors are calculated for no-slip conditions at the walls. The asymptotic values of the Nusselt numbers, friction factors. incremental pressure drops, axial velocity and momentum rate and kinetic energy correction factors approach the available fully developed values. Various geometrical dimensions of the cross-section are considered.     

Turbulent flow in a ribbed channel: Flow structures in the vicinity of a rib

PIV measurements are performed in a channel with periodic ribs on one wall. The emphasis of this study is to investigate the flow structures in the vicinity of a rib in terms of mean velocities, Reynolds stresses, probability density functions (PDF), and two-point correlations. The PDF distribution of u′ is bimodal in the separated shear layer downstream of the rib. The maximum Reynolds shear stresses occur at the leading edge of the rib. Based on quadrant analysis, it is found that ejection motions make a dominant contribution to the Reynolds shear stress in this region. Moreover, topology-based visualization is applied to the separation bubble upstream of the rib. Salient critical points and limit cycles are extracted, which gives clues to the physical processes occurring in the flow.     

Flow pattern based correlations of two-phase pressure drop in rectangular microchannels

Numerous pressure drop correlations for microchannels have been proposed; most of them can be classified as either a homogeneous flow model (HFM) or a separated flow model (SFM). However, the predictions of these correlations have not been compared directly because they were developed in experiments conducted under a range of conditions, including channel shape, the number of channels, channel material and the working fluid. In this study, single rectangular microchannels with different aspect ratios and hydraulic diameters were fabricated in a photosensitive glass. Adiabatic water-liquid and Nitrogen-gas two-phase flow experiments were conducted using liquid superficial velocities of 0.06–1.0 m/s, gas superficial velocities of 0.06–72 m/s and hydraulic diameters of 141, 143, 304, 322 and 490 μm. A pressure drop in microchannels was directly measured through embedded ports. The flow pattern was visualized using a high-speed camera and a long-distance microscope. A two-phase pressure drop in the microchannel was highly related to the flow pattern. Data were used to assess seven different HFM viscosity models and ten SFM correlations, and new correlations based on flow patterns were proposed for both HFMs and SFMs.     

Pressure drop prediction with a modified frictional-kinetic model for alumina in bypass pneumatic conveying system

A new frictional-kinetic model is proposed and modified for pressure drop prediction of alumina in a bypass pneumatic conveying system. This new model is based on the conventional Johnson–Jackson frictional-kinetic model. The critical value of solids volume fraction and maximum packing limit are modified based on the fluidized bulk density and tapped bulk density, respectively. In addition, an offset solid volume fraction is introduced into the frictional pressure model as well as into the radial distribution functions which represents the correction factors to modify the probability of collisions between particles when solid phase becomes excessively dense. For the application of the model, computational fluid dynamics (CFD) simulations were conducted by using kinetic theory, conventional frictional-kinetic model and modified frictional-kinetic model. The simulation results were then compared with the experimental results. It was found that the modified frictional-kinetic model showed the largest improvement on pressure drop prediction results compared with results obtained from applying the kinetic theory and the conventional frictional-kinetic model, especially for denser flows with low air mass flow rates and high solid loading ratios (SLR). In addition, the solids volume investigation of CFD simulations shows a strong comparison to the actual flow conditions in the pipe, as transient slug type flow of alumina is observed.