Experimental and analytical study of the effect of contact angle on liquid convective heat transfer in microchannels

In this paper we examine the effect of contact angle (or surface wettability) on the convective heat transfer coefficient in microchannels. Slip flow, where the fluid velocity at the wall is non-zero, is most likely to occur in microchannels due to its dependence on shear rate or wall shear stress. We show analytically that for a constant pressure drop, the presence of slip increases the Nusselt number. In a microchannel heat exchanger we modified the surface wettability from a contact angle of 20 degrees-120 degrees using thin film coating technology. Apparent slip flow is implied from pressure and flow rate measurements with a departure from classical laminar friction coefficients above a critical shear rate of approximately 10,000 s(-1). The magnitude of this departure is dependant on the contact angle with higher contact angles surfaces exhibiting larger pressure drop decreases. Similarly, the non-dimensional heat flux is found to decrease relative to laminar non-slip theory, and this decrease is also a function of the contact angle. Depending on the contact angle and the wall shear rate, variations in the heat transfer rate exceeding 10% can be expected. Thus the contact angle is an important consideration in the design of micro, and even more so, nano heat exchangers. (c) 2006 Elsevier Ltd. All rights reserved.

Methods of detecting fouling caused by heating of milk

Fouling is the deposition of milk solids on heat transfer sur aces, particularly heat exchangers. It is a major industrial problem, which causes a decrease in heat transfer efficiency and shortens run times. The resultant effect is a decrease in process efficiency and economy. For studying and monitoring deposit formation, suitable fouling detectors or methods of measuring the deposit are required. This can be achieved through direct means, whereby the deposit is analyzed after a certain time, or indirectly through instrumentation for monitoring parameters such as temperature, pressure, flow rate, overall heat transfer coefficient, heat flux, and other physical properties. This article reviews the various reported fouling detection methods.

Erosion-corrosion of mild steel in hot caustic. Part I: NaOH solution

A novel apparatus, high-pressure/high-temperature nickel flow loop, was constructed to study the effect of the flow on the rate of erosion-corrosion of mild steel in hot caustic. It has been successfully used to measure the corrosion rate of 1020 steel in 2.75 M NaOH solution at a temperature of 160 degrees C and velocities of 0.32 and 2.5 m/s. In situ electrochemical methods were used to measure the corrosion rate such as the potentiodynamic sweep, the polarization resistance method, and electrochemical impedance spectroscopy (EIS). Also used were the weight-loss method and scanning electron microscopy (SEM). Eight electrodes/coupons were used to monitor the metal loss rate, four were placed at the low velocity section, while the other four were placed in the high velocity section. The first three coupons in each section were placed within the disturbed flow region, while the fourth was placed in a fully developed flow region. The corrosion rate of the coupons in the high velocity section was generally higher than that of the coupons in the low velocity section. One coupon in the disturbed flow region had a significantly higher corrosion rate than the others. (c) 2005 Elsevier Ltd. All rights reserved.

Using computational fluid dynamics in combating erosion-corrosion

Computational fluid dynamics was used to search for the links between the observed pattern of attack seen in a bauxite refinery's heat exchanger headers and the hydrodynamics inside the header. Validation of the computational fluid dynamics results was done by comparing then with flow parameters measured in a 1:5 scale model of the first pass header in the laboratory. Computational fluid dynamics simulations were used to establish hydrodynamic similarity between the 1:5 scale and full scale models of the first pass header. It was found that the erosion-corrosion damage seen at the tubesheet of the first pass header was a consequence of increased levels of turbulence at the tubesheet caused by a rapidly turning flow. A prismatic flow corrections device introduced in the past helped in rectifying the problem at the tubesheet but exaggerated the erosion-corrosion problem at the first pass header shell. A number of alternative flow correction devices were tested using computational fluid dynamics. Axial ribbing in the first pass header and an inlet flow diffuser have shown the best performance and were recommended for implementation. Computational fluid dynamics simulations have revealed a smooth orderly low turbulence flow pattern in the second, third and fourth pass as well as the exit headers where no erosion-corrosion was seen in practice. This study has confirmed that near-wall turbulence intensity, which can be successfully predicted by using computational fluid dynamics, is a good hydrodynamic predictor of erosion-corrosion damage in complex geometries. (c) 2006 Published by Elsevier Ltd.

Hydrogen from coal: Production and utilisation technologies

Error condition detected Although coal may be viewed as a dirty fuel due to its high greenhouse emissions when combusted, a strong case can be made for coal to be a major world source of clean H-2 energy. Apart from the fact that resources of coal will outlast oil and natural gas by centuries, there is a shift towards developing environmentally benign coal technologies, which can lead to high energy conversion efficiencies and low air pollution emissions as compared to conventional coal fired power generation plant. There are currently several world research and industrial development projects in the areas of Integrated Gasification Combined Cycles (IGCC) and Integrated Gasification Fuel Cell (IGFC) systems. In such systems, there is a need to integrate complex unit operations including gasifiers, gas separation and cleaning units, water gas shift reactors, turbines, heat exchangers, steam generators and fuel cells. IGFC systems tested in the USA, Europe and Japan employing gasifiers (Texaco, Lurgi and Eagle) and fuel cells have resulted in energy conversions at efficiency of 47.5% (HHV) which is much higher than the 30-35% efficiency of conventional coal fired power generation. Solid oxide fuel cells (SOFC) and molten carbonate fuel cells (MCFC) are the front runners in energy production from coal gases. These fuel cells can operate at high temperatures and are robust to gas poisoning impurities. IGCC and IGFC technologies are expensive and currently economically uncompetitive as compared to established and mature power generation technology. However, further efficiency and technology improvements coupled with world pressures on limitation of greenhouse gases and other gaseous pollutants could make IGCC/IGFC technically and economically viable for hydrogen production and utilisation in clean and environmentally benign energy systems. (c) 2005 Elsevier B.V. All rights reserved.

Double-heater-wire circuits and heat-and-moisture exchangers and the risk of ventilator-associated pneumonia

Objective: To compare the incidence of ventilator-associated pneumonia (VAP) in patients ventilated in intensive care by means of circuits humidified with a hygroscopic heat-and-moisture exchanger with a bacterial viral filter (HME) or hot-water humidification with a heater wire in both inspiratory and expiratory circuit limbs (DHW) or the inspiratory limb only (SHW). Design: A prospective, randomized trial. Setting: A metropolitan teaching hospital's general intensive care unit. Patients: Three hundred eighty-one patients requiring a minimum period of mechanical ventilation of 48 hrs. Interventions: Patients were randomized to humidification with use of an HME (n = 190), SHW (n = 94), or DHW (n = 97). Measurements and Main Results. Study end points were VAP diagnosed on the basis of Clinical Pulmonary Infection Score (CPIS) (1), HME resistance after 24 hrs of use, endotracheal tube resistance, and HME use per patient. VAP occurred with similar frequency in all groups (13%, HME; 14%, DHW; 10%, SHW; p = 0.61) and was predicted only by current smoking (adjusted odds ratio [AOR], 2.1; 95% confidence interval [CI], 1.1-3.9; p =.03) and ventilation days (AOR, 1.05; 95% Cl, 1.0-1.2; p =.001); VAP was less likely for patients with an admission diagnosis of pneumonia (AOR, 0.40; 95% Cl, 0.4-0.2; p =.04). HME resistance after 24 hrs of use measured at a gas flow of 50 L/min was 0.9 cm H2O (0.4-2.9). Endotracheal tube resistance was similar for all three groups (16-19 cm H2O min/L; p =.2), as were suction frequency, secretion thickness, and blood on suctioning (p =.32, p =.06, and p =.34, respectively). The HME use per patient per day was 1.13. Conclusions: Humidification technique does not influence either VAP incidence or secretion characteristics, but HMEs may have air-flow resistance higher than manufacturer specifications after 24 hrs of use.