Ultra fast cooling of hot steel plate by air atomized spray with salt solution

In the present study, the applicability of air atomized spray with the salt added water has been studied for ultra fast cooling (UFC) of a 6 mm thick AISI-304 hot steel plate. The investigation includes the effect of salt (NaCl and MgSO₄) concentration and spray mass flux on the cooling rate. The initial temperature of the steel plate before the commencement of cooling is kept at 900 °C or above, which is usually observed as the “finish rolling temperature” in the hot strip mill of a steel plant. The heat transfer analysis shows that air atomized spray with the MgSO₄ salt produces 1.5 times higher cooling rate than atomized spray with the pure water, whereas air atomized spray with NaCl produces only 1.2 times higher cooling rate. In transition boiling regime, the salt deposition occurs which causes enhancement in heat transfer rate by conduction. Moreover, surface tension is the governing parameter behind the vapour film instability and this length scale increases with increase in surface tension of coolant. Overall, the achieved cooling rates produced by both types of salt added air atomized spray are found to be in the UFC regime.     

Effect of EHD on heat transfer enhancement during two-phase condensation of R-134a at high mass flux in a horizontal smooth tube

In this study, effect of electrohydrodynamic (EHD) on the condensation heat transfer enhancement and pressure drop of pure R-134a are experimentally investigated. The test section is a 2.5 m long counterflow double tube heat exchanger with refrigerant flowing in the inner tube and cooling water flowing in the annulus. The inner tube is made from smooth horizontal copper tubing of 9.52 mm outer diameter. The electrode is made from stainless steel wire of 1.47 mm diameter. The test runs are performed at average saturated temperatures ranging between 40 and 60°C, mass flux ranging between 200 and 600 kg/m² s, heat flux ranging between 10 and 20 kW/m² and applied voltage at 2.5 kV. For the presence of the electrode, the experimental results indicate that the maximum heat transfer enhancement ratio is around 30% while the maximum increase in pressure drop is about 25%.     

Hybrid turbulence simulation of spray impingement cooling: The effect of vortex motion on turbulent heat flux

Spray impingement has been a major interest of researchers in the areas of spray cooling, internal combustion, fire suppression and spray cooling, etc. for a long time. Numerous studies have been done in the area of spray cooling. Spray cooling with phase change takes advantage of relatively large amounts of latent heat and is capable of removing high heat fluxes from the surface, which has generated the interest of many researchers. In this paper, the turbulent characteristics of vapor formed during the spray impingement are studied. Water and gasoline are used in the numerical analysis of the two‐phase spray impingement on a heated wall. Hybrid turbulence modeling was used for the analysis where the subgrid scale model was employed away from the wall and k–ε model was used near the wall. Gasoline, at 298 K, was sprayed on the heated wall, kept constant at 650 K. The surrounding temperature was maintained at 400 K at the start of the simulation. In case of water and gasoline at Reynolds number 2750, the heated wall was kept constant at 400 K and the surrounding temperature was maintained at 298 K at the start of the simulations. The nozzle diameter of 100µm was used for this study, with the nozzle plate spacing ratio at 10. The spray was impinged on the flat plate at angles of 0, 15, and 30^°. Root mean‐squared velocities and turbulent heat flux were plotted in the water spray impingement for the different angles of impingement. The effect of turbulence on the heat transfer was observed. The effect of vortex motion on the turbulent heat flux values was analyzed using different Reynolds numbers of impingement and at different angles in case of gasoline. The turbulent heat flux attained the maximum values with high vortex formation. Upwash of fluid transported heat away from the wall, producing higher heat flux values in the region. Copyright © 2008 John Wiley & Sons, Ltd.     

Thermal diagnostics of highly heated surfaces using water-spray cooling

Spray cooling of heated surfaces is common in many industrial applications, notably steelmaking, because of its high heat dissipating ability. Control of the surface heat flux rate contributes to better products; it is shown that the heat transfer rate depends on the mass fraction of liquid. Quantitative information regarding the parameters affecting spray cooling is relatively scarce. The rate of heat transfer from a plate due to impinging of an array of water jets was investigated numerically through the solution of heat conduction equation. The simulation is carried out for eight different sprayers, in the range of ejected fluid pressure between 1 bar and 3 bars. Experimental data are used to study the influence of the function g(x, y), of dispersed water, on heat transfer variations across the surface at the temperature of 600°C. Curves were generated showing time histories of the steel temperature for the removal of high heat fluxes of the order of 300 W/cm². It was also observed that for lower temperatures, the predicted local heat transfer coefficient increased significantly. In memory of H. Mzad’s father Mebrouk.     

Large area impingement spray cooling from multiple normal and inclined spray nozzles

An inclined spray chamber with four multiple nozzles to cool a 1 kW 6U electronic test card has been designed and tested in this study. The multiple inclined sprays can cover the same heated surface area as that with the multiple normal sprays but halve the volume of the spray chamber. The spray cooling system used R134a as a working fluid in a modified refrigeration cycle. It is observed that increasing mass flow rate and pressure drop across the nozzles improved the heat transfer coefficient with a maximum enhancement of 117 %, and reduced the maximum temperature difference at the heated surface from 13.8 to 8.4 °C in the inclined spray chamber with a heat flux of 5.25 W/cm², while the heat transfer coefficient of the normal spray increased with a maximum enhancement of 215 % and the maximum temperature difference decreased from 10.8 to 5.4 °C under similar operating conditions. We conclude that the multiple inclined sprays could produce a higher heat transfer coefficient but with an increase in non-uniformity of the surface temperature compared with the multiple normal sprays.     

Numerical simulation of an innovated building cooling system with combination of solar chimney and water spraying system

In this study, passive cooling of a room using a solar chimney and water spraying system in the room inlet vents is simulated numerically in Yazd, Iran (a hot and arid city with very high solar radiation). The performance of this system has been investigated for the warmest day of the year (5 August) which depends on the variation of some parameters such as water flow rate, solar heat flux, and inlet air temperature. In order to get the best performance of the system for maximum air change and also absorb the highest solar heat flux by the absorber in the warmest time of the day, different directions (West, East, North and South) have been studied and the West direction has been selected as the best direction. The minimum amount of water used in spraying system to set the inside air averaged relative humidity <65 % is obtained using trial and error method. The simulation results show that this proposed system decreases the averaged air temperature in the middle of the room by 9–14 °C and increases the room relative humidity about 28–45 %.     

Effect of heater size on ultrasonic enhancement of boiling in water and surfactant solutions

Experiments were performed to study enhancement of heat transfer from the wire of d = 50 µm and the tube of d = 1.5 mm in subcooled pool boiling by ultrasonic waves. The working fluids are clean water and Alkyl (8-16) Glucoside surfactant solutions of different concentrations and bulk temperature 30 °C. The wire resistance was translated to the temperature, using the calibration data, the temperature of the tube was measured by thermocouple. The differences between effect of ultrasonic field on boiling in water for heaters of d = 50 µm and d = 1.5 mm may be summarized as follows: for boiling on the wire of d = 50 µm in subcooled water, T_b = 30 °C, enhancement of heat transfer coefficient due to applied ultrasonic field is about 70% and 20% at heat flux q = 620 kW/m² and q = 1350 kW/m², respectively. For boiling in surfactant solutions at the same boiling conditions enhancement of heat transfer coefficient is in the range of 5–10% at heat flux q = 620 kW/m² and 10–16% at heat flux q = 1350 kW/m² depending on solution concentration. For boiling on the tube of d= 1.5 mm in subcooled water, T_b= 30 ℃, enhancement of heat transfer coefficient due to applied ultrasonic field is about 50% and 45% at heat flux q = 500 kW/m² and q = 2500 kW/m², respectively. The same values are obtained for boiling in surfactant solution of concentration C = 250 ppm. For the wire of d = 50 µm the heat transfer enhancement due to acoustic vibrations in surfactant solutions is not as strong as in water. This fact may be considered as evidence of significant role of relationship between jet flow and ultrasonic field.     

The influence of oil on nucleate pool boiling heat transfer

The influence of various oil contents in R134a is investigated for nucleate pool boiling on copper tubes either sandblasted or with enhanced heating surfaces (GEWA-B tube). Polyolester oils (POE) (Reniso Triton) with medium viscosity 55 cSt (SE55) and high viscosity 170 cSt (SE170) were used. Heat transfer coefficients were obtained for boiling temperatures between −28.6 and +20.1°C. The oil content varied from 0 to 5% mass fraction. For the sandblasted tube and the SE55 oil the heat transfer coefficients for the refrigerant/oil-mixture can be higher or lower than those for the pure refrigerant, depending on oil mass fraction, boiling temperature and heat flux. In some cases the highest heat transfer coefficients were obtained at a mass fraction of 3%. For the 170 cSt oil there is a clear decrease in heat transfer for all variations except for a heat flux 4,000 W/m² and −10.1°C at 0.5% oil content. The heat transfer coefficients are compared to those in the literature for a smooth stainless steel tube and a platinum wire. For the enhanced tube and 55 cSt oil the heat transfer coefficients are clearly below those for pure refrigerant in all cases. The experimental results for the sandblasted tube are compared with the correlation by Jensen and Jackman. The calculated values are within +20 and −40% for the medium viscosity oil and between +50% and −40% for the high viscosity oil. A correlation for predicting oil-degradation effects on enhanced surfaces does not exist.     

Boiling heat transfer region with independence of the wall temperature

 Extensive measurements of the intensive cooling of hot-rolled wires with temperatures between 1000 ^°C and 1100 ^°C are analysed. The analysis proves the existence of a convection-controlled boiling region, which has been previously observed by few authors in the case of high mass fluxes and high liquid subcooling. This region is characterised by an independence of the heat flux of the surface temperature. The heat flux depends essentially on the Reynolds number, the main influence parameter of the single phase convection, and on the liquid subcooling. Received on 13 September 1999     

Local heat transfer from a hot plate to a water jet

Jet impingement boiling is very efficient in cooling of hot surfaces as a part of the impinging liquid evaporates. Because of its importance to many cooling procedures, investigations on basic mechanisms of jet impingement boiling heat transfer are needed. Until now, most of the experimental studies, carried out under steady-state conditions, used a heat flux controlled system and were limited by the critical heat flux (CHF). The present study focuses on steady-state experiments along the entire boiling curve for hot plate temperatures of up to 700°C. A test section has been built up simulating a hot plate. It is divided into 8 independently heated modules of 10 mm length to enable local heat transfer measurements. By means of temperature controlled systems for each module local steady-state experiments in the whole range between single phase heat transfer and film boiling are possible. By solving the two dimensional inverse heat conduction problem, the local heat flux and the corresponding wall temperature on the surface of each module can be computed. The measurements show important differences between boiling curves measured at the stagnation line and those obtained in the parallel flow region. At the stagnation line, the transition boiling regime is characterised by very high heat fluxes, extended to large wall superheats. Inversely, boiling curves in the parallel flow region are very near to classical ones obtained for forced convection boiling. The analysis of temperature fluctuations measured at a depth of 0.8 mm from the boiling surface enables some conclusions on the boiling mechanism in the different boiling regimes.     

Heat transfer during transient cooling of high temperature surface with an impinging jet

 An experimental study of transient boiling heat transfer during a cooling of a hot cylindrical block with an impinging water jet has been made at atmospheric pressure. The experimental data were taken for the following conditions: a degree of subcooling of ΔT _sub = 20–80 K, a jet velocity of u _j  = 5–15 m/s, a nozzle diameter of d _j  = 2 mm and three materials of copper, brass and carbon steel. The block was initially and uniformly heated to about 250 °C and the transient temperatures in the block were measured at eight locations in r-direction at two different depths from the surface during the cooling of hot block. The surface heat flux distribution with time was evaluated using a numerical analysis of 2-D heat conduction. Behavior of the wetting front, which is extending the nucleate boiling region outward, is observed with a high-speed video camera. A position of wetting region is measured and it is correlated well with a power function of time. The changes in estimated heat flux and temperature were compared with the position of wetting region to clarify the effects of subcooling, jet velocity and thermal properties of block on the transient cooling. Received on 17 March 2000     

Experimental investigation on heat transfer of forced convection condensation of ethanol–water vapor mixtures on a vertical mini-tube

In this paper, condensation heat transfer characteristics of ethanol–water vapor mixtures on a vertical mini-vertical tube with 1.221 mm outside diameter were investigated experimentally. The experiments were performed at different velocities and pressures over a wide range of ethanol mass fractions in vapor. The test results indicated that, with respect to the change of the vapor-to-surface temperature difference, the condensation curves of the heat transfer coefficients revealed nonlinear characteristics, and had peak values. At 2 % ethanol mass fraction in vapor, the condensation heat transfer coefficient value of the ethanol–water vapor mixture was found to have a maximum heat transfer coefficient of 50 kW m^?2 K^?1, which was 3–4 times than that of pure steam. The condensation heat transfer coefficients decreased with increased ethanol mass fraction in vapor. The vapor pressure and vapor velocity had a positive effect on the condensation heat transfer coefficients of ethanol–water vapor mixtures.     

Flow boiling heat transfer of R134a and R404A in a microfin tube at low mass fluxes and low heat fluxes

An experimental investigation of flow boiling heat transfer in a commercially available microfin tube with 9.52 mm outer diameter has been carried out. The microfin tube is made of copper with a total fin number of 55 and a helix angle of 15°. The fin height is 0.24 mm and the inner tube diameter at fin root is 8.95 mm. The test tube is 1 m long and is electrically heated. The experiments have been performed at saturation temperatures between 0 and −20°C. The mass flux was varied between 25 and 150 kg/m²s, the heat flux from 15,000 W/m² down to 1,000 W/m². All measurements have been performed at constant inlet vapour quality ranging from 0.1 to 0.7. The measured heat transfer coefficients range from 1,300 to 15,700 W/m²K for R134a and from 912 to 11,451 W/m²K for R404A. The mean heat transfer coefficient of R134a is in average 1.5 times higher than for R404A. The mean heat transfer coefficient has been compared with the correlations by Koyama et al. and by Kandlikar. The deviations are within ±30% and ±15%, respectively. The influence of the mass flux on the heat transfer is most significant between 25 and 62.5 kg/m²s, where the flow pattern changes from stratified wavy flow to almost annular flow. This flow pattern transition is shifted to lower mass fluxes for the microfin tube compared to the smooth tube.     

Condensation heat transfer characteristics of R-22, R-134a and R-410A in small diameter tubes

The condensation heat transfer of pure refrigerants, R-22, R-134a and a binary refrigerant R-410A flowing in small diameter tubes was investigated experimentally. The condenser is a countflow heat exchanger which refrigerant flows in the inner tube and cooling water flows in the annulus. The heat exchanger is smooth, horizontal copper tube of 1.77, 3.36 and 5.35 mm inner diameter, respectively. The length of heat exchanger is 1220, 2660 and 3620 mm, respectively. The experiments were conducted at mass flux of 200–400 kg/m² s and saturation temperature of 40°C. The main results were summarized as follows: in case of single-phase flow, the single-phase Nusselt Number measured by experimental data was higher than that calculated by Gnielinski and Wu and Little correlation. The new single-phase correlation based on the experimental data was proposed in this study. In case of two-phase flow, the condensation heat transfer coefficient of R-410A for three tubes was slightly higher than that of R-22 and R-134a at the given mass flux. The condensation heat transfer coefficient of R-22 showed almost a similar value to that of R-134a. The condensation heat transfer coefficient for R-22, R-134a and R-410A increased with increasing mass flux and decreasing tube diameter. Most of the existing correlations which were proposed in the large diameter tube failed to predict condensation heat transfer. Therefore, the new condensation heat transfer correlation based on the experimental data was proposed in the present study.     

Heat transfer associated to a hot surface quenched by a jet of oil-in-water emulsion

In hot rolling, the mechanical properties of steel alloys are conditioned by the rolling process but a great part is ensured by the cooling of the hot strip mill. Well controlling this cooling rate and its homogeneity is thus of primary importance for obtaining steels with desired mechanical properties. As the water used in the cooling stage of the rolling process can be polluted by oil (in hot mill strip, some oil is used to lubricate the rolls and a part of it can pollute the water), it is important to know how much varies the cooling rates when water is polluted. In this study, transient cooling has been investigated during quenching of a hot metal disk with various subcooled oil-in-water emulsion jets. The aim of this work is to compare the cooling efficiency of oil-in-water emulsion jet with a pure water jet. Experimental investigations of axisymmetric jet impingements on a preheated hot metal disk (500-600 °C) have been performed with various oil-in-water emulsions. The transient cooling heat fluxes on the quenched side are estimated by coupling the measurement of the temperature field of the other side (rear face) with a semi-analytical inverse heat conduction model.     

Evaporation heat transfer and flow characteristics of R-134a flowing through internally grooved tubes

This article describes experimental investigations of the heat transfer coefficient and pressure drop of R-134a flowing inside internally grooved tubes. The test tubes are one smooth tube and four grooved tubes. All test tubes are made from type 304 stainless steel, have an inner diameter of 7.1 mm, are 2,000 mm long and are installed horizontally. The test section is uniformly heated by a DC power supply to create evaporation conditions. The groove depth of all grooved tubes is fixed at 0.2 mm. The experimental conditions are conducted at saturation temperatures of 20, 25 and 30°C, heat fluxes of 5, 10 and 15 kW/m², and mass fluxes of 300, 500 and 700 kg/m² s. The effects of groove pitch, mass flux, heat flux, and saturation temperature on heat transfer coefficient and frictional pressure drop are discussed. The results illustrate that the grooved tubes have a significant effect on the heat transfer coefficient and frictional pressure drop augmentations.     

Theoretical and experimental studies on air gap membrane distillation

Air gap membrane distillation (AGMD) is an innovative membrane separation technique for pure water extraction from aqueous solutions. In this study, both theoretical and experimental investigations are carried out on AGMD of different aqueous solutions, namely, tap water, salted water, dyed solutions, acid solutions, and alkali solutions. A simple mechanistic model of heat and mass transfer associated with AGMD is developed. Simple relationships of permeate flux, total heating or cooling load and thermal efficiency of AGMD with respect to the membrane distillation temperature difference are obtained. Effects of solution concentration and the width of the air gap in AGMD are analyzed. In the experimental study, the experiments were conducted using 1m PTFE membrane with a membrane distillation temperature difference up to 55^∘C. The AGMD system yields a permeate flux of pure water of up to 28kg/m²h. Direct comparison of the experimental results with the proposed modeling predictions shows a fairly good match. Received on 19 May 1998     

Experimental verification of heat transfer coefficient for nucleate boiling at sub-atmospheric pressure and small heat fluxes

In this paper we study the influence of sub-atmospheric pressure on nucleate boiling. Sixteen correlations for pool boiling available in literature are gathered and evaluated. Analysis is performed in the pressure range 1–10 kPa and for heat flux densities 10–45 kW/m². Superheats are set between 6.2 and 28.7 K. The results of calculations were compared with experimental values for the same parameters. The experiments were conducted using isolated glass cylinder and water boiling above the copper plate. Results show that low pressure adjust the character of boiling curve—the curve flattened and the natural convection region of boiling is shifted towards higher wall temperature superheats due to the influence of low pressure on the bubble creation and process of its departure. In result, 8 of 16 analyzed correlations were determined as completely invalid in subatmospheric conditions and the remaining set of equations was compared to experimental results. Experimentally obtained values of heat transfer coefficients are between 1 and 2 kW/m²K. With mean absolute deviation (MAD) we have found that the most accurate approximation of heat transfer coefficient is obtained using Mostinski reduced pressure correlation (0.13–0.35 MAD) and Labuntsov correlation (0.12–0.89 MAD).     

Pool boiling of drag-reducing polymer solutions

The effect of drag-reducing polymeric additives on the critical heat flux and minimum film boiling temperature in subcooled pool boiling of water has been experimentally examined. Three water-soluble polymers, viz. a polyethylene oxide (Aldrich No. 18946-4), a polyacrylamide (Separan AP-30), and a galactomannan polysaccharide (Galactasol-211) have been examined at concentrations of 10, 50, and 100 wppm. The experiment is performed by quenching a hot brass sphere in an isothermal pool of the fluid to be examined and obtaining the corresponding boiling curve. The experiments have been conducted at atmospheric pressure with a pool temperature of 90°C. The results show that the critical heat flux increases by more than 50% while the minimum film boiling temperature increases by more than 110°C when concentrations of 100 wppm of polyox or guar gum are used. For separan solutions, the critical heat flux and minimum film boiling temperature are lower than those for water and go through a minimum at a concentration of ～10 wppm; the maximum reductions are about 73% and 34°C respectively.     

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.