An experimental investigation of flow boiling in an asymmetrically heated rectangular microchannel

By using unique experimental techniques and carefully constructed experimental apparatus, the characteristics of flow boiling of water in microscale were investigated using a single horizontal rectangular microchannel. A polydimethylsiloxane rectangular microchannel (D_h = 103.5 and 133 μm) was fabricated by using the replica molding technique, a kind of soft lithography. A piecewise serpentine platinum microheater array on a Pyrex substrate was fabricated with the surface micromachining MEMS technique. Real time flow visualization of the phase change phenomena inside the microchannel was performed using a high speed CCD camera with microscope. The experimental local boiling heat transfer coefficients were studied, and single bubble inception, growth, and departure, as well as elongated bubble behavior were analyzed to elucidate the microscale heat transfer mechanisms. Tests were performed for mass fluxes of 77.5, 154.9, and 309.8 kg/m² s and heat fluxes of 180–500 kW/m². The effects of mass flux, heat flux, and vapor qualities on flow boiling heat transfer in a microchannel were studied.     

Thermal and hydraulic performance of a three-phase fluidized bed cooling tower

An experimental study was made of the thermal and hydraulic characteristics of a three-phase fluidized bed cooling tower. The experiments were carried out in a packed tower of 200 mm diameter and 2.5 m height. The packing used was spongy rubber balls 12.7 mm in diameter and with a density of 375 kg/m³. The tower characteristic was evaluated. The air-side pressure drop and the minimum fluidization velocity were measured as a function of water/air mass flux ratio (0.4–2), static bed height (300–500 mm), and hot water inlet temperature (301–334 K).

The experimental results indicate that the tower characteristics KaV/L increases with increases in the bed static height and hot water inlet temperature and with decreases in the water/air mass flux ratio. It is also shown that the air-side pressure drop increases very slowly with increases in air velocity. The minimum, fluidization velocity was found to be independent of the static bed height.

The data obtained were used to develop a correlation between the tower characteristics, hot water inlet temperature, static bed height, and the water/air mass flux ratio. The mass transfer coefficient of the three-phase fluidized bed cooling tower is much higher than that of packed-bed cooling towers with higher packing height.     

Prediction of refrigerant void fraction in horizontal tubes using probabilistic flow regime maps

A state of the art review of two-phase void fraction models in smooth horizontal tubes is provided and a probabilistic two-phase flow regime map void fraction model is developed for refrigerants under condensation, adiabatic, and evaporation conditions in smooth, horizontal tubes. Time fraction information from a generalized probabilistic two-phase flow map is used to provide a physically based weighting of void fraction models for different flow regimes. The present model and void fraction models in the literature are compared to data from multiple sources including R11, R12, R134a, R22, R410A refrigerants, 4.26–9.58 mm diameter tubes, mass fluxes from 70 to 900 kg/m² s, and a full quality range. The present model has a mean absolute deviation of 3.5% when compared to the collected database.     

Elongated bubbles in microchannels. Part I: Experimental study and modeling of elongated bubble velocity

The velocity of elongated vapor bubbles exiting two horizontal micro-evaporator channels with refrigerant R-134a was studied. Experiments with tube diameters of 509 and 790 μm, mass velocities from 200 to 1500 kg/m² s, vapor qualities from 2% to 19% and a nominal saturation temperature of 30 °C were analyzed with a fast, high-definition digital video camera. It was found from image processing of numerous videos that the elongated bubble velocity relative to that of homogeneous flow increased with increasing bubble length until a plateau was reached, and also increased with increasing channel diameter and increasing mass velocity. Furthermore an analytical model developed for a diabatic two-phase flow, has been proposed that is able to predict these trends. In addition, the model shows that the relative elongated bubble velocity should decrease with increasing pressure, which is consistent with the physics of two-phase flow.     

Shroud heat transfer measurements inside a heated multiple rotating cavity with axial throughflow

Experimental measurements of heat transfer are made from the inner peripheral surface of a rotating test rig designed to be similar to a gas turbine high pressure compressor internal air system. The test rig comprises a number of annular discs sealed at their periphery by a shroud. An axial throughflow of cooling air enters the test rig and flows through the annular section between the disc bores and a central shaft. Tests were carried out for the following range of rotational speeds and axial throughflow rates: 540 < N_R < 10,800 rev/min and (corresponding to the range of rotational and axial Reynolds numbers 4 × 10⁵ < Re < 7.7 × 10⁶ and 3.3 × 10⁴ < Re_z < 2.2 × 10⁵).

The shroud Nusselt numbers are found to depend on the shroud Grashof number. They are relatively insensitive to changes in axial Reynolds number and two geometrically similar cavities give similar values of Nusselt number. The heat transfer from the shroud is governed by the mechanism of free convection. It is recommended that a modified form of a correlation for Rayleigh–Bénard convection in a gravitational force field be used, with appropriate modification, to predict shroud heat transfer.     

Flow boiling visualization in a vertical circular minichannel at high vapor quality

This paper reports on an experimental study of saturated flow boiling of R134a inside a circular vertical quartz tube coated with a transparent heater. The inner diameter of the tube was 1.33 mm and the heated length 235.5 mm. The flow pattern at high vapor qualities and the dryout of the liquid film were studied using a high speed CCD camera at the mass fluxes 47.4 and 124.4 kg/m² s in up flow at 6.425 bar. The heat fluxes ranged from 5 to 13.6 kW/m² for the lower mass flux and from 20 to 32.4 kW/m² for the higher mass flux.

The behavior of the flow close to dryout was found to be different at low and high mass flux. At low mass flux the location of the liquid front fluctuated with waves passing high up in the tube. In between the waves, a thin film was formed, slowly evaporating without breaking up.

At high mass flux the location of the liquid front was more stable. In this case the liquid film was seen to break up into liquid streams and dry zones on the tube wall.     

Heat transfer analysis according to condensation flow structures in a minichannel

An experimental investigation of complete condensation flow is undertaken for a range of mass flow rates between 3.4 and 13.8 kg/m² s. The associated flow regimes are visualized using an ombroscopic technique. Two major flows are observed (with or without release of bubbles). A critical value of the mass flow rate is obtained at the transition between these two regimes. The visualization also enables a local parameter to be determined: the void fraction. The influence of the presence of a bubbly zone is highlighted by the heat transfer and pressure drops. Finally, the dependence of the critical value of the mass flow rate on the temperature of the secondary flow is obtained.     

Convective boiling of halocarbon refrigerants flowing in a horizontal copper tube – an experimental study

An experimental study of convective boiling of refrigerants R-22, R-134a and R-404A in a 12.7 mm internal diameter, 2 m long, horizontal copper tube has been performed. Experiments involved a relatively wide range of operational conditions. Experiments were performed at the evaporating temperatures of 8°C and 15°C. Quality, mass velocity and heat flux varied in the following ranges: 5% to saturated vapor, 50–500 kg/(s m²); and 5–20 kW/m². Effects of these physical parameters over the heat transfer coefficient have been investigated. High quality experiments were also performed up to the point of the tube surface dryout, a mechanism which was investigated from the qualitative point of view. Two heat transfer coefficient correlations from the literature have been evaluated through comparisons with experimental data. Deviations varied in the range from −25% to 42%.     

An experimental investigation of combined turbulent free and forced evaporation

The wide variation in correlations available in the literature for predicting water evaporation rates in a moving air stream necessitated a new investigation to determine which correlations can be considered reliable. Water evaporation measurements were made from a heated pool (a class-A pan) into a low speed wind tunnel. The evaporation regime examined combined turbulent free and turbulent forced convection over the range 0.1 < Gr_m/Re² < 10.0. The data includes the range in which combined convection modes are important, as well as the limits where either free or forced convection effects may dominate. The data are compared to several evaporation correlations based on laboratory wind tunnel data. These historical correlations do not produce consistent estimates in predicting evaporation rates. It is believed that the apparent inconsistencies arise because many correlations do not adequately describe the appropriate evaporation regimes for which they are valid. A new correlation using the combined free/forced convection Sherwood number has been developed to predict evaporation rates for a moving air stream. This correlation allows the results of this study to be extended to other evaporating conditions (i.e. variation in surface geometry and air turbulence levels) than those described here. For a 95% confidence limit, the Sherwood number correlation matches the data within ±7.9%.     

Effects of fuel properties on the burning characteristics of collision-merged alkane/water droplets

The combustion characteristics of freely falling droplets, individually generated by the merging of colliding alkane and water droplets, were experimentally investigated. The outcome of the collision droplets was firstly studied and then the subsequent burning processes such as the flame appearance, ignition and burning behaviors were recorded, through either visual observation or microphotography with the aid of stroboscopic lightening. If the merged droplets were exhibited in an insertive manner, while the water droplet inserted into the alkane droplet, these yield the burning behaviors prior to the end of flame were very much similar to that of pure alkane. The burning was ended with droplet extinction for lower-C alkane, and with either droplet “flash vaporization” or extinction for hexadecane. And if the merged droplets were in adhesive manner, for hexadecane with large water content, they either could not be ignited for the large merged droplets, or be ignited with a much prolonged ignition delay, followed by a soot-reducing flame and an ending of droplet extinction for the small merged droplets. “Homogeneous” explosion was not observed in any of the tests, and “heterogeneous” explosion, induced by trapped air bubbles, occasionally occurred for merged droplets with C-atom in alkane is higher than dodecane. And the sudden disappearance of droplet definitely decreased the burning time and thus enhanced the burning intensity. Besides, the fuel mass consumption rates were increased, even in the cases that having droplet extinction, because of the enlargement of the surface area due to the stuffing of water droplet.     

Heat transfer in bubble layers at elevated pressures

Heat transfer with steam condensation under moderate pressure on the surface of a horizontal tube immersed in a bubbling layer was experimentally investigated. A copper test section 16 mm in outer diameter and 400 mm in length was placed in a bubbling column 455 mm in diameter. Experiments were made under pressures of 0.14–0.8 MPa, with void fraction 0.04–0.23, vapor superficial velocities 0.05–0.42 m/s, liquid-wall temperature differences 47–105 K, and heat flux densities 0.12–0.8 MW/m². The heat transfer process in the bubbling layer is shown to be of a high intensity: with moderate values of steam content, heat transfer coefficients reach 12–14 kW/(m² · K). Data obtained showed that the known correlations do not consider the influence of pressure on heat transfer. For the first time, data on radial steam content distribution under pressures higher than atmospheric were obtained by an electroprobe method. A table of experimental data is presented.     

Heat transfer in bubble layers at high pressures

An original experimental investigation of heat transfer with steam condensation on a surface of a horizontal cooled tube immersed in a bubbling layer was carried out. A copper test section 16 mm in diameter and 285 mm in length was placed in a bubbling column 295 mm in diameter. Experiments were made under a pressure of 0.72-3.8 MPa with volume steam content 0-0.18, steam superficial velocities 0-0.18 m/s, and liquid-wall temperature difference 38–106 K. The heat transfer process in a bubbling layer under high pressures is shown to be of considerably intensity; with moderate values of steam content heat transfer coefficients reach 10–12 kW/(m²·K). The use of the known correlations assumed for the case of air bubbling under atmospheric pressure results in systematically underestimating heat transfer by 30–80%. Data were obtained on heat transfer with film condensation of steam and natural convection of subcooled water at high temperature differences outside the range investigated earlier. Experimental data table is appended.     

Computational and experimental study of annular photo-reactor hydrodynamics

The performance of ultraviolet (UV) reactors used for water treatment is greatly influenced by the reactor hydrodynamics due to the non-homogeneity of the radiation field. Reliable modeling of the reactor flow structures is therefore crucial for the design process. In this study, the turbulent flow through two characteristic annular UV-reactor configurations, with inlets concentric (L-shape) and normal (U-shape) to the reactor axis, was investigated through computational fluid dynamic (CFD). The modeling results were evaluated with the velocity profiles from particle image velocimetry (PIV) experiments. The influence of mesh structure and density, as well as three turbulence models: Standard κ–, Realizable κ–, and Reynolds stress model (RSM), on the simulation results were evaluated. Mesh-independent solutions were achieved at mean cell volumes of 5 × 10⁻⁹ m³. The Realizable κ– displayed the best overall match to the experimental PIV measurements. In general, the CFD models showed a close agreement with the experimental data for the majority of the reactor domain and captured the influences of reactor configuration and internal reactor structures on the flow distribution. The validated CFD hydrodynamic models could be integrated with kinetic and radiation distribution models for UV-reactor performance simulation.     

Experimental study on the condensation of supersonic steam jet submerged in quiescent subcooled water: Steam plume shape and heat transfer

The condensation of supersonic steam jet submerged in the quiescent subcooled water was investigated experimentally. The results indicated that the shape of steam plume was controlled by the steam exit pressure and water temperature. Six different shapes of steam plume were observed under the present test conditions. Their distribution as a function of the steam exit pressures and water temperatures was given. As the steam mass velocity and water temperature increase, the measured maximum expansion ratio and dimensionless penetration length of steam plume were in the ranges of 1.08–1.95 and 3.05–13.15, respectively. The average heat transfer coefficient of supersonic steam jet condensation was found to be in the range of 0.63–3.44 MW/m²K. An analytical model of steam plume was found and the correlations to predict the maximum expansion ratio, dimensionless penetration length and average heat transfer coefficient were also investigated.     

Two-phase flow measurements with sharp-edged orifices

This paper contains the results of a set of two-phase flow measurements of 4 different ratios of vapor to liquid density (up to 0.328) across a sharp-edged circular orifice. Test fluid was R-113. Tests were carried out upon 3 orifices whose diameter ratios were 0.312, 0.439 and 0.625. The test quality ranged from 0–100%, while the mass velocity from 917–1477 kg/m².s. On the basis of a modified separated flow model, a relationship is developed for the flow rate and quality and is compared with experimental data and 5 proposed correlations. Comparison shows this method can be used to calculate the flow rate or the quality of vapor liquid (or steam water) mixture in the range 0.00455 to 0.328 of the density ratio, and in pipe size ranging from 8 to 75 mm (β = 0.25–0.75).

The RMS error of this method is about 12% when the quality, x, ranges from 2% to 100%.     

Kinetics of ultrafine coating of SiO2 nanoparticles, suspended in non-thermal CH4/C2H6 plasma

Capacitively coupled RF discharges in methane and ethane (1000–3000 Pa, 5–15 W/cm³) were used for the in-flight coating of SiO₂ nanopowders (NP) with an a-C:H layer [A. Kouprine, F. Gitzhofer, M. Boulos, A. Fridman, Polymer-like C:H thin film coating of nanopowders in capacitively coupled RF discharge, Plasma Chemistry and Plasma Processing 24 (2) (2004) 189–215]. In this present work a model of the chemical kinetics of this plasma processing has been developed, based on the GRI-Mech 3.0 mechanism [G.P. Smith, D.M. Golden, M. Frenklach, Gas Research Institute, Detailed chemical reaction mechanism. Available from: ], and calculations are performed, using the Chemkin-II code. The model includes the formation of two solid phases: an amorphous C:H coating, deposited on the suspended NP, and soot, incepted in the gas phase. Non-equilibrium plasma effects are taken into account by the rates of radical species’ production, using the reference data on the “G-value”. The CH₃ and H species appear to have key roles in surface activation and the nanofilm growth. The results demonstrate the competitive character of the formation of the two solid phases: the C:H coating is dominant under T_gas < 1400–1600 K, depending on the conditions, and soot commencing to dominate at higher temperatures. This division corresponds to the passage from non-thermal plasma conditions, with the dominance of single-valent radicals and solid phase growth on the substrate only, to the plasma thermalisation with the formation of two-valent radicals and v. inception of the solid phase. The results are validated experimentally by the observation of soot formation as a function of the gas temperature, by the mass spectrograph data on the gas composition after plasma reforming, and by the reference data on coating growth rates and induction times for soot formation.     

Experimental and numerical studies on the burning of aluminum micro and nanoparticle clouds in air

An experimental study has been conducted to determine flame propagation velocities in clouds of micro- (4.8 μm) and nano- (187 nm) aluminum particles in air at various concentrations. The experimental results show faster flame propagation in nanoparticle cloud with respect to the case of microparticles. Maximum flame temperature has been measured using a high-resolution spectrometer operating in the visible range. Analysis of combustion residual shows that nanoparticles combustion is realized via the gas-phase mechanism. A three-stage particle combustion model has been proposed based on these observations. Model parameters have been fitted to match the experimental results on the flame velocity and maximum temperature. Particle burning time is estimated from the flame simulations.     

Explosive vaporization in microenclosures

The explosive vaporization of a liquid above planar microheaters induces a fast increase of pressure that is exploited in many thermally driven actuators in MEMS components such as ink jet printer cartridges, pumps, valves and optical switches. Some of these components need to enclose the working fluid as it is the case of valves in which the heated liquid is separated from the flow that it regulates by a flexible membrane. To achieve a better insight into the thermodynamic processes involved, the present work investigates experimentally an enclosed microsystem designed and fabricated for this purpose, composed of a small liquid volume (8 nL) heated by a electric pulse for 2 μs supplied to a planar microfabricated heater. During the heating, the temperature-induced change in resistance can be determined by imposing a defined current and measuring the voltage drop over the heater. While the chip is based on a silicon substrate with integrated platinum heaters and sensors, the structure enclosing the fluid (cavity and fluidic access to it) is made of a silicone elastomer, poly(dimethylsiloxane) (PDMS). This transparent material is widely used in microfluidics and allows for flexible and transparent walls that can be deflected by increasing the pressure inside the cavity. To seal the system the inlet and the outlet were closed by blocking them with a metallic stab. In the present work we visualize vaporization of isopropanol in contact with a suddenly heated planar resistor for two different cavity heights, 150 μm and 16 μm. The rate of temperature rise of the thin liquid layer in contact with the heater is of the order of 10⁷ K s⁻¹ for a pulse duration of 2 μs. We compare bubble growth and collapse for the open and closed systems. Compared to the open system, the bubble growth in the closed system is considerably damped.     

粉尘火焰加速现象的实验研究

粉尘火焰的发生、加速及由爆燃向爆轰转捩的机理是个至今尚未弄清的问题。需要解决的技术关键之一是在实验室实现弱点火条件下的粉尘火焰加速直至达到爆轰状态。着手发展了一种球形喷粉扬尘装置，令产生的扬尘湍流在水平实验管中形成空间均匀分布和维持秒级悬浮的粉尘云状态。采用以上扬尘装置的水平实验管，在６ｇ黑火药的六点平面点火条件下获得了微细铝粉火焰经５ｍ长的传播过程加速至１０００ｍ／ｓ的实验结果。给出了扬尘湍流强度、粉尘粒度与浓度、点火能量及方式等因素对粉尘火焰加速过程中所起作用，及变截面效应（由小变大）对粉尘火焰减速的影响。