Surface wettability effect on flow pattern and pressure drop in adiabatic two-phase flows in rectangular microchannels with T-junction mixer

Wettability is an important parameter in micro-scale flow patterns. Previous research has usually been conducted in conventional microtubes due to limitations of visualizing flow patterns and fabricating microchannels. However, most microchannels in practical applications have rectangular shape. Furthermore, pressure drop is closely related with flow pattern. Hence, we studied water liquid and nitrogen gas flows in rectangular microchannels with different wettabilities. The rectangular glass microchannels were fabricated from photosensitive glass, whose surface is hydrophilic. The surface of one was silanized using octadecyl-trichloro-silane (OTS) to prepare a hydrophobic microchannel. The two-phase flow pattern was visualized with a high-speed camera and a long distance microscope. The frictional pressure drop in the microchannel was measured directly with embedded pressure ports. The flow pattern and pressure drop in the hydrophobic microchannel were totally different from those in the hydrophilic microchannel. Finally, the two-phase frictional pressure drop was analyzed based on the flow patterns of different wettabilities.     

An Experimental Study of Mobilization and Creeping Flow of Oil Slugs in a Water-Filled Capillary

An experimental investigation was carried out on mobilization and very slow flow of oil slugs in a capillary tube. The pressure drop of the slug flow was measured at every stage of mobilizing and moving the oil slugs as a function of capillary number in the range of 4 × 10⁻⁷–6 × 10⁻⁶. The pressure drop across the oil slug experienced three stages: build-up, hold-up, and steady stages. During the build-up stage, the convex rear end of the slug was becoming concave into the oil slug and the convex front end of the slug moved ahead to form a new portion of the slug. At the hold-up stage, both the concave rear end and the front end continued to advance, and the initial contact line of the oil slug with the tube wall through a very thin water film was being shortened. At this stage, the pressure drop reached a maximum value and remained nearly constant. At the steady stage, after the oil slug was completely mobilized out of the original contact region, the differential pressure had a step-drop first, and then the oil slug flowed at a lower differential pressure depending on the flow rate. Numerous slug flow tests of this study showed that the hold-up pressure drop was always higher than the steady stage pressure drop. Results also showed that the measured extra pressure drop was significantly high compared to the pressure drop calculated from Poiseuille equation, which is still commonly used in network modeling of multiphase flow in porous media.     

Pressure drop in two phase slug/bubble flows in mini scale capillaries

A segmented two phase slug/bubble flow occurs where a liquid and a gas are pumped into the same tube over a range of Reynolds numbers. This segmented two phase flow regime is accompanied by an increase in pressure drop relative to the single phase flow where only one fluid is flowing in a capillary. This work experimentally and theoretically examines the pressure drop encountered by the slug/bubble flow with varying slug lengths in mini channels. In the experimental work the dimensionless parameters of Reynolds number and Capillary number span over three orders of magnitude, and dimensionless slug length ranges over two orders of magnitude to represent flows typical of mini- and micro-scale systems. It is found, in agreement with previous work, that these dimensionless groups provide the correct scaling to represent the pressure drop in two phase slug/bubble flow, although the additional pressure drop caused by the interface regions was found to be ∼40% less than previously reported.     

Measurement of liquid film thickness in micro square channel

In micro channels, slug flow becomes one of the main flow regimes due to strong surface tension. In micro channel slug flow, elongated bubble flows with the thin liquid film confined between the bubble and the channel wall. Liquid film thickness is an important parameter in many applications, e.g., micro heat exchanger, micro reactor, coating process etc. In the present study, liquid film thickness in micro square channels is measured locally and instantaneously with the confocal method. Square channels with hydraulic diameter of D_h = 0.3, 0.5 and 1.0 mm are used. In order to investigate the effect of inertial force on the liquid film thickness, three working fluids, ethanol, water and FC-40 are used. At small capillary numbers, liquid film at the channel center becomes very thin and the bubble interface is not axisymmetric. However, as capillary number increases, bubble interface becomes axisymmetric. Transition from non-axisymmetric to axisymmetric flow pattern starts from lower capillary number as Reynolds number increases. An empirical correlation for predicting axisymmetric bubble radius based on capillary number and Weber number is proposed from the present experimental data.     

Gas–liquid two-phase flows in rectangular polymer micro-channels

This study addresses gas–liquid two-phase flows in polymer (PMMA) micro-channels with non-molecularly smooth and poorly wetting walls (typical contact angle of 65°) unlike previous studies conducted on highly wetting molecularly smooth materials (e.g., glass/silicon). Four fundamentally different topological flow regimes (Capillary Bubbly, Segmented, Annular, Dry) were identified along with two transitory ones (Segmented/Annular, Annular/Dry) and regime boundaries were identified from the two different test chips. The regime transition boundaries were influenced by the geometry of the two-phase injection, the aspect ratio of the test micro-channels, and potentially the chip material as evidenced from comparisons with the results of previous studies. Three principal Segmented flow sub-regimes (1, 2, and 3) were identified on the basis of quantified topological characteristics, each closely correlated with two-phase flow pressure drop trends. Irregularity of the Segmented regimes and related influencing factors were addressed and discussed. The average bubble length associated with the Segmented flows scaled approximately with a power law of the liquid volumetric flow ratio, which depends on aspect ratio, liquid superficial velocity, and the injection system. A simplified semi-empirical geometric model of gas bubble and liquid plug volumes provided good estimates of liquid plug length for most of the segmented regime cases and for all test-channel aspect ratios. The two-phase flow pressure drop was measured for the square test channels. Each Segmented flow sub-regime was associated with different trends in the pressure drop scaled by the viscous scale. These trends were explained in terms of the quantified flow topology (measured gas bubble and liquid plug lengths) and the number of bubble/plug pairs. Significant quantitative differences were found between the two-phase pressure drop in the polymer micro-channels of this study and those obtained from previous glass/silicon micro-channel studies, indicating that the effect of wall surface properties is important. Pressure drop trends on the capillary scale along gas bubbles extracted from the measurements in square micro-channels indicated a linear dependence on the Capillary number and did not agree with those predicted by highly idealized theory primarily because explicit and implicit assumptions in the theory were not relevant to practical conditions in this study.     

Flow boiling behaviors in hydrophilic and hydrophobic microchannels

Surface wettability is a critical parameter in small scale phenomena, especially two-phase flow, since the surface force becomes dominant as size decreases. In present study, experiments of water flow boiling in hydrophilic and hydrophobic rectangular microchannels were conducted to investigate the wettability effect on flow boiling in rectangular microchannels. The rectangular microchannels were fabricated with a photosensitive glass to visualize flow pattern. The hydrophilic bare photosensitive glass microchannel was chemically treated to obtain a hydrophobic microchannel. And, visualization of flow patterns was carried out. And boiling heat transfer and two-phase pressure drop was analyzed with visualization results. The boiling heat transfer coefficient in the hydrophobic rectangular microchannel was higher than that in the hydrophilic rectangular microchannel, which was highly related with nucleation site density and liquid film motion. And the pressure drop in the hydrophobic rectangular microchannel was higher than that in the hydrophilic rectangular microchannel, which was highly related with unstable motions of bubble and liquid film. Finally, we find out the wettability is important parameter on the flow pattern, which were highly related with two-phase heat and mass transfer.     

Interfacial flows in corrugated microchannels: Flow regimes,transitions and hysteresis

We report simulations of gas–liquid two-phase flows in microchannels periodically patterned with grooves and ridges. A constant effective body force is applied on both fluids to simulate a pressure-driven creeping flow, and a diffuse-interface model is used to compute the interfacial evolution and the contact line motion. Depending on the body force, capillary force and the level of liquid saturation, a number of flow regimes may appear in the corrugated microchannel: gas flow, blockage, liquid flow, bubble–slug flow, droplet flow, annular flow and annular-droplet flow. A map of flow regimes is constructed for a set of geometric and flow parameters starting from a prescribed initial configuration. Some of the regimes are new, while others have been observed before in straight tubes and pipes. The latter are compared with previous experiments in terms of the regime map and the holdup ratio. The transition among flow regimes shows significant hysteresis, largely owing to the pinning of the interface at sharp corners in the flow conduit. Hysteresis is reduced if the sharp corners are rounded. Under the same operating conditions, different flow regimes can be realized from different initial conditions. The roles of geometry and wettability of the channel walls are also elucidated.     

Viscous dissipation effect on heat transfer characteristics of rectangular microchannels under slip flow regime and H1 boundary conditions

Viscous dissipation effect on heat transfer characteristics of a rectangular microchannel is studied. Flow is governed by the Navier–Stokes equations with the slip flow and temperature jump boundary conditions. Integral transform technique is applied to derive the temperature distribution and Nusselt number. The velocity distribution is taken from literature. The solution method is verified for the case where viscous dissipation is neglected. It is found that, the viscous dissipation is negligible for gas flows in microchannels, since the contribution of this effect on Nu number is about 1%. However, this effect should be taken into account for much more viscous flows, such as liquid flows. Neglecting this effect for a flat microchannel with an aspect ratio of 0.1 for Br=0.04 underestimates the Nu number about 5%.     

A hybrid method for bubble geometry reconstruction in two-phase microchannels

Understanding bubble dynamics is critical to the design and optimization of two-phase microchannel heat sinks. This paper presents a hybrid experimental and computational methodology that reconstructs the three-dimensional bubble geometry, as well as provides other critical information associated with nucleating bubbles in microchannels. Rectangular cross-section silicon microchannels with hydraulic diameters less than 200 μm were fabricated with integrated heaters for the flow experiments, and the working liquid used was water. Bubbles formed via heterogeneous nucleation and were observed to grow from the silicon side walls of the channels. Two-dimensional images and two-component liquid velocity field measurements during bubble growth were obtained using micron-resolution particle image velocimetry (μPIV). These measurements were combined with iterative three-dimensional numerical simulations using finite element software, FEMLAB. The three-dimensional shape and location of the bubble were quantified by identifying the geometry that provided the best match between the computed flow field and the μPIV data. The reconstructed flow field through this process reproduced the experimental data within an error of 10–20%. Other important information such as contact angles and bubble growth rates can also be estimated from this methodology. This work is an important step toward understanding the physical mechanisms behind bubble growth and departure.     

Single cavitation bubble generation and observation of the bubble collapse flow induced by a pressure wave

This study utilizes a U-shape platform device to generate a single cavitation bubble for a detailed analysis of the flow field characteristics and the cause of the counter jet during the process of bubble collapse caused by sending a pressure wave. A high speed camera is used to record the flow field of the bubble collapse at different distances from a solid boundary. It is found that a Kelvin–Helmholtz vortex is formed when a liquid jet penetrates the bubble surface after the bubble is compressed and deformed. If the bubble center to the solid boundary is within one to three times the bubble’s radius, a stagnation ring will form on the boundary when impinged by the liquid jet. The fluid inside the stagnation ring will be squeezed toward the center of the ring to form a counter jet after the bubble collapses. At the critical position, where the bubble center from the solid boundary is about three times the bubble’s radius, the bubble collapse flow will vary. Depending on the strengths of the pressure waves applied, the collapse can produce a Kelvin–Helmholtz vortex, the Richtmyer–Meshkov instability, or the generation of a counter jet flow. If the bubble surface is in contact with the solid boundary, the liquid jet can only move inside-out without producing the stagnation ring and the counter jet; thus, the bubble collapses along the radial direction. The complex phenomenon of cavitation bubble collapse flows is clearly manifested in this study.     

Forced convective flow and heat transfer of upward cocurrent air–water slug flow in vertical plain and swirl tubes

This experimental study comparatively examined the two-phase flow structures, pressured drops and heat transfer performances for the cocurrent air–water slug flows in the vertical tubes with and without the spiky twisted tape insert. The two-phase flow structures in the plain and swirl tubes were imaged using the computerized high frame-rate videography with the Taylor bubble velocity measured. Superficial liquid Reynolds number (Re_L) and air-to-water mass flow ratio (AW), which were respectively in the ranges of 4000–10000 and 0.003–0.02 were selected as the controlling parameters to specify the flow condition and derive the heat transfer correlations. Tube-wise averaged void fraction and Taylor bubble velocity were well correlated by the modified drift flux models for both plain and swirl tubes at the slug flow condition. A set of selected data obtained from the plain and swirl tubes was comparatively examined to highlight the impacts of the spiky twisted tape on the air–water interfacial structure and the pressure drop and heat transfer performances. Empirical heat transfer correlations that permitted the evaluation of individual and interdependent Re_L and AW impacts on heat transfer in the developed flow regions of the plain and swirl tubes at the slug flow condition were derived.     

An investigation on near wall transport characteristics in an adiabatic upward gas–liquid two-phase slug flow

The near-wall transport characteristics, inclusive of mass transfer coefficient and wall shear stress, which have a great effect on gas–liquid two-phase flow induced internal corrosion of low alloy pipelines in vertical upward oil and gas mixing transport, have been both mechanistically and experimentally investigated in this paper. Based on the analyses on the hydrodynamic characteristics of an upward slug unit, the mass transfer in the near wall can be divided into four zones, Taylor bubble nose zone, falling liquid film zone, Taylor bubble wake zone and the remaining liquid slug zone; the wall shear stress can be divided into two zones, the positive wall shear stress zone associated with the falling liquid film and the negative wall shear stress zone associated with the liquid slug. Based on the conventional mass transfer and wall shear stress characteristics formulas of single phase liquid full-pipe turbulent flow, corrected normalized mass transfer coefficient formula and wall shear stress formula are proposed. The calculated results are in good agreement with the experimental data. The shear stress and the mass transfer coefficient in the near wall zone are increased with the increase of superficial gas velocity and decreased with the increase of superficial liquid velocity. The mass transfer coefficients in the falling liquid film zone and the wake zone of leading Taylor bubble are lager than those in the Taylor bubble nose zone and the remaining liquid slug zone, and the wall shear stress associated falling liquid film is larger than that associated the liquid slug. The mass transfer coefficient is within 10⁻³ m/s, and the wall shear stress below 10³ Pa. It can be concluded that the alternate wall shear stress due to upward gas–liquid slug flow is considered to be the major cause of the corrosion production film fatigue cracking.     

Seed bubbles stabilize flow and heat transfer in parallel microchannels

Seed bubbles are generated on microheaters located at the microchannel upstream and driven by a pulse voltage signal, to improve flow and heat transfer performance in microchannels. The present study investigates how seed bubbles stabilize flow and heat transfer in micro-boiling systems. For the forced convection flow, when heat flux at the wall surface is continuously increased, flow instability is self-sustained in microchannels with large oscillation amplitudes and long periods. Introduction of seed bubbles in time sequence improves flow and heat transfer performance significantly. Low frequency (∼10 Hz) seed bubbles not only decrease oscillation amplitudes of pressure drops, fluid inlet and outlet temperatures and heating surface temperatures, but also shorten oscillation cycle periods. High frequency (∼100 Hz or high) seed bubbles completely suppress the flow instability and the heat transfer system displays stable parameters of pressure drops, fluid inlet and outlet temperatures and heating surface temperatures. Flow visualizations show that a quasi-stable boundary interface from spheric bubble to elongated bubble is maintained in a very narrow distance range at any time. The seed bubble technique almost does not increase the pressure drop across microsystems, which is thoroughly different from those reported in the literature. The higher the seed bubble frequency, the more decreased heating surface temperatures are. A saturation seed bubble frequency of 1000–2000 Hz can be reached, at which heat transfer enhancement attains the maximum degree, inferring a complete thermal equilibrium of vapor and liquid phases in microchannels. Benefits of the seed bubble technique are the stabilization of flow and heat transfer, decreasing heating surface temperatures and improving temperature uniformity of the heating surface.     

Bubble generation and transport in a microfluidic device with high aspect ratio

Bubble generation and transport in a micro-device composed of a micro-T-junction and a following serpentine micro-channel was experimentally investigated. It has a rectangular cross-sectional with an aspect ratio of 7.425. Air and water were used as gas and liquid, respectively. Mixtures of water–glycerol and water–Tween-20 were used to study the effects of liquid viscosity and surface tension. Compared with previous T-junction bubble generation, the liquid and gas inlets orientation was switched in this work. The continuous flow was driven from the perpendicular channel and the dispersion flow was from the main channel. It shows that the break-up process has three periodic steps under certain operating conditions. The dimensionless bubble length L/w in the micro-channel with high aspect ratio is much larger than that in square microchannels. A correlation is proposed to correlate L/w with liquid flow rate J_L, gas flow rate J_G, and liquid viscosity μ_L. Surface tension σ can change the bubble shape but almost does not affect the bubble length in this fast break-up process. Additionally, a long bubble may be broken up at the corners at the same time because the locations of gas and liquid are exchanged relative to the concave and convex portions of an elbow after a turn which may result in the change of fluid velocities and gas–liquid pressure drop.     

An updated three-zone heat transfer model for slug flow boiling in microchannels

This work proposes a novel physics-based model for the fluid mechanics and heat transfer associated with slug flow boiling in horizontal circular microchannels to update the widely used three-zone model of Thome et al. (2004). The heat transfer model has a convective boiling nature and predicts the time-dependent variation of the local heat transfer coefficient during the cyclic passage of a liquid slug, an evaporating elongated bubble and a vapor plug. The capillary flow theory, extended to incorporate evaporation effects, is applied to estimate the bubble velocity along the channel. A liquid film thickness prediction method also considering bubble proximity effects, which may limit the radial extension of the film, is included. The minimum liquid film thickness at dryout is set to the channel wall roughness. Theoretical heat transfer models accounting for the thermal inertia of the liquid film and for the recirculating flow within the liquid slug are utilized. The heat transfer model is compared to experimental data taken from three independent studies. The 833 slug flow boiling data points cover the fluids R134a, R245fa and R236fa, and channel diameters below 1 mm. The proposed evaporation model predicts more than 80% of the database to within ±30%. It demonstrates a stronger contribution to heat transfer by the liquid slugs and correspondingly less by the thin film evaporation process compared to the original three-zone model. This model represents a new step towards a complete physics-based modelling of the bubble dynamics and heat transfer within microchannels under evaporating flow conditions.     

Convective and diffusive surfactant transfer in multiphase liquid systems

Laser interferometry was used to investigate diffusive and convective mass transfer in a multicomponent fluid mixture with a liquid–liquid or liquid–gas interface. For this purpose, an immobile gas bubble or insoluble fluid droplet, having the shape of a short cylinder with a free lateral surface, was inserted into a thin liquid layer. In the case of non-uniform distribution of the dissolved surfactant component, the Marangoni convection near the drop/bubble was initiated by the surface tension inhomogeneities, depending on the surfactant concentration. The applied experimental techniques allowed us to study the structure and evolution of the convective flows and concentration fields in a liquid layer, which due to its small thickness were nearly two-dimensional. Making use of both the vertical and horizontal orientation of the liquid layer, we investigated the mass transfer process at different levels of the interaction between gravity and capillary forces. During the experiments, we detected new solutocapillary phenomena, which were found to be caused by oscillatory regimes of solutal convection occurring around air bubbles and chlorobenzene drops in heterogeneous aqueous solutions of alcohol with a vertical surfactant concentration gradient. The role of the oscillatory instability in the processes of drop saturation by the surfactant from its water solution and an inverse process of surfactant extraction from the drop into the surrounding homogeneous fluid (water) was determined. A reasonable explanation for the driving mechanisms of the discovered effects has been proposed.     

Cahn–Hilliard/Navier–Stokes Model for the Simulation of Three-Phase Flows

In this article, we describe some aspects of the diffuse interface modelling of incompressible flows, composed of three immiscible components, without phase change. In the diffuse interface methods, system evolution is driven by the minimisation of a free energy. The originality of our approach, derived from the Cahn–Hilliard model, comes from the particular form of energy we proposed in Boyer and Lapuerta (M2AN Math Model Numer Anal, 40:653–987,2006), which, among other interesting properties, ensures consistency with the two-phase model. The modelling of three-phase flows is further completed by coupling the Cahn–Hilliard system and the Navier–Stokes equations where surface tensions are taken into account through volume capillary forces. These equations are discretized in time and space paying attention to the fact that most of the main properties of the original model (volume conservation and energy estimate) have to be maintained at the discrete level. An adaptive refinement method is finally used to obtain an accurate resolution of very thin moving internal layers, while limiting the total number of cells in the grids all along the simulation. Different numerical results are given, from the validation case of the lens spreading between two phases (contact angles and pressure jumps), to the study of mass transfer through a liquid/liquid interface crossed by a single rising gas bubble. The numerical applications are performed with large ratio between densities and viscosities and three different surface tensions.     

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.     

Experimental study on interfacial area transport of a vertical downward bubbly flow

In relation to the development of the interfacial area transport equation, local flow measurements of vertical downward air–water flows in a pipe with an inner diameter of 50.8 mm were performed at three axial locations of z/D=6.50, 34.0, and 66.5 as well as ten radial locations from r/R=0 to r/R=0.9 using a multi-sensor probe. In the experiment, the superficial liquid velocity and the void fraction ranged from –0.620 m/s to –2.49 m/s and from 0.21% to 8.4%, respectively. The dependence of the interfacial area transport on the liquid velocity, void fraction, and bubble size is discussed in detail.     

Analysis of the characteristic lengths in the bubble and slug flow regimes generated in a capillary T-junction

We present an analysis of the geometry of the continuous and disperse phases in the bubble and slug flow regimes in air–water mixtures generated in a capillary T-junction of 1  mm internal diameter. Bubble size dispersion is very low in the considered flow patterns. The concept of unit cell is used to identify two characteristic lengths of the two-phase flow, namely, the unit cell length and the bubble length. The relationship between these lengths and the gas and liquid superficial velocities, gas mean velocity, bubble generation frequency and volume average void fraction is analysed. We conclude that in the considered configuration the unit cell and bubble lengths can be predicted either by the ratio of the gas–liquid superficial velocities or the volume average void fraction.