Numerical study of heat transfer in laminar film boiling by the finite-difference method

The finite-difference form of the basic conservation equations in laminar film boiling have been solved by the false-transient method. By a judicious choice of the coordinate system the vapour-liquid interface is fitted to the grid system. Central differencing is used for diffusion terms, upwind differencing for convection terms, and explicit differencing for transient terms. Since an explicit method is used the time step used in the false-transient method is constrained by numerical instability. In the present problem the limits on the time step are imposed by conditions in the vapour region. On the other hand the rate of convergence of finite-difference equations is dependent on the conditions in the liquid region. The rate of convergence was accelerated by using the over-relaxation technique in the liquid region. The results obtained compare well with previous work and experimental data available in the literature.

Forced convection film boiling of subcooled water around a sphere

An experimental investigation was made of forced convection film boiling of subcooled water around a sphere at atmospheric pressure. The water was sufficiently cool that the vapor condensed before leaving the film with the result that no vapor bubbles left the film. The experimental runs were made using inductively heated spheres at temperatures above 740°C. and using inlet water temperatures between 15°C. and 27°C. The spheres used had diameters of 1/2 inch, 9/16 inch, and 3/8 inch and were supported by the liquid flow. Reynolds numbers between 60 and 700 were used.

Analysis of the collected non-condensables indicated that oxygen and nitrogen dissolved in the water accumulated within the vapor film and that hetrogeneous chemical reactions occurred at the sphere surface. An iron-steam reaction resulted in more than 20% by volume hydrogen in the film at wall temperatures above 900°C. At temperatures near 1100°C. more than 80% by volume of the film was composed of hydrogen. It was found that gold plating of the sphere could eliminate this reaction.

Material and energy balances were used to derive equations which may be used to predict the overall average heat transfer coefficients for subcooled film boiling around a sphere. These equations include the effect of dissolved gases in the water. Equations also were derived which may be used to predict the composition of the film for cases in which an equilibrium exists between the dissolved gases and the gases in the film.

The derived equations were compared to the experimental results. It was found that a correlation existed between the Nusselt number for heat transfer from the vapor-liquid interface into the liquid and the Reynolds number, liquid Prandtl number product. In addition, it was found that the percentage of dissolved oxygen removed during the film boiling could be predicted to within 10%.

Transition to Film Boiling in Microgravity: Influence of Subcooling

The transition process to film pool boiling in microgravity is studied experimentally aboard the Chinese recoverable satellite SJ-8. A quasi-steady heating method is adopted, in which the heating voltage is controlled to increase exponentially with time. Small, primary bubbles are formed and slid on the surface, which coalesce with each other to form a large coalesced bubble. Two ways are observed for the transition from nucleate to film boiling at different subcoolings. At high subcooling, the coalesced bubble with a smooth surface grows slowly. It is then difficult for the coalesced bubble to cover the whole heater surface, resulting in a special region of transition boiling in which nucleate boiling and local dry areas can coexist. In contrast, strong oscillation of the coalesced bubble surface at low subcooling may cause rewetting of local dry areas and activation of more nucleate sites, resulting in an abrupt transition to film boiling.

Model laws for the transition from nucleate to film boiling with forced convection /

"Report title: Theoretical investigations of the transition from bubble boiling to film boiling at forced convection"--p. v.

Subcooled Pool Boiling at Microgravity: Preliminary Ground-Based Experimental Results

A temperature-controlled pool boiling (TCPB) device was developed to perform pool boiling heat transfer studies at both normal gravity on Earth and microgravity in the drop tower Beijing and aboard a Chinese recovery satellite. Two platinum wires of 60 ?m in diameter were simultaneously used as heaters and thermometers. The lengths were 30 mm and 40 mm, respectively. The ends of wires were soldered with copper poles to provide low resistance paths for the electric current. The heater resistance, and thus the heater temperature, was kept constant by a feedback circuit similar to that used in constant-temperature hot-wire anemometry. The fluid was R113 at 0.1 Mpa and subcooled by 30 ?C nominally for all cases. The results of the experiments at normal gravity were presented. Four modes, namely single-phase convection, nucleate boiling, transition two-mode boiling, and film boiling were observed. A few data obtained from several preliminary experiments at microgravity in the drop tower Beijing were also presented. A slight increase of the heat flux was obtained.

Bubble Behavior and Heat Transfer in Quasi-Steady Pool Boiling in Microgravity

Pool boiling of degassed FC-72 on a plane plate heater has been studied experimentally in microgravity. A quasi-steady heating method is adopted, in which the heating voltage is controlled to increase exponentially with time. Compared with terrestrial experiments, bubble behaviors are very different, and have direct effect on heat transfer. Small, primary bubbles attached on the surface seem to be able to suppress the activation of the cavities in the neighborhoods, resulting in a slow increase of the wall temperature with the heat flux. For the high subcooling, the coalesced bubble has a smooth surface and a small size. It is difficult to cover the whole heater surface, resulting in a special region of gradual transitional boiling in which nucleate boiling and local dry area can co-exist. No turning point corresponding to the transition from nucleate boiling to film boiling can be observed. On the contrary, the surface oscillation of the coalesced bubble at low subcooling may cause more activated nucleate sites, and then the surface temperature may keep constant or even fall down with the increasing heat flux. Furthermore, an abrupt transition to film boiling can also be observed. It is shown that heat transfer coefficient and CHF increase with the subcooling or pressure in microgravity, as observed in normal gravity.

Integrated fluid-thermal-structural numerical analysis for the quenching of metallic components

The quenching of a metal component with a channel section in a water tank is numerically simulated. Computational fluid dynamics (CFD) is used to model the multiphase flow and the heat transfer in film boiling, nucleate boiling and convective cooling processes to calculate the difference in heat transfer rate around the component and then combining with the thermal simulation and structure analysis of the component to study the effect of heat transfer rate on the distortion of the U-channel component. A model is also established to calculate the residual stress produced by quenching. The coupling fluid-thermal-structural simulation provides an insight into the deformation of the component and can be used to perform parameter analysis to reduce the distortion of the component. © 2011 Shanghai Jiaotong University and Springer-Verlag Berlin Heidelberg.

Metodología de simulación numérica de la transferencia de calor por ebullición en película en torno a superficies esféricas refrigeradas por líquido saturado en convección libre: aplicación a reactores nucleares de lecho de bolas (PBR)

En la presente Tesis se realizó un análisis numérico, usando el código comercial Ansys-Fluent, de la refrigeración de una bola de combustible de un reactor de lecho de bolas (PBR, por sus siglas en inglés), ante un escenario de emergencia en el cual el núcleo sea desensamblado y las bolas se dejen caer en una piscina de agua, donde el mecanismo de transferencia de calor inicialmente sería la ebullición en película, implicando la convección y la radiación al fluido. Previamente se realizaron pruebas de validación, comparando los resultados numéricos con datos experimentales disponibles en la literatura para tres geometrías diferentes, lo cual permitió seleccionar los esquemas y modelos numéricos con mejor precisión y menor costo computacional. Una vez identificada la metodología numérica, todas las pruebas de validación fueron ampliamente satisfactorias, encontrándose muy buena concordancia en el flujo de calor promedio con los datos experimentales. Durante estas pruebas de validación se lograron caracterizar numéricamente algunos parámetros importantes en la ebullición en película con los cuales existen ciertos niveles de incertidumbre, como son el factor de acoplamiento entre convección y radiación, y el factor de corrección del calor latente de vaporización. El análisis térmico de la refrigeración de la bola del reactor por ebullición en película mostró que la misma se enfría, a pesar del calor de decaimiento, con una temperatura superficial de la bola que desciende de forma oscilatoria, debido al comportamiento inestable de la película de vapor. Sin embargo, la temperatura de esta superficie tiene una buena uniformidad, notándose que las áreas mejor y peor refrigeradas están localizadas en la parte superior de la bola. Se observó la formación de múltiples domos de vapor en diferentes posiciones circunferenciales, lo cual causa que el área más caliente de la superficie se localice donde se forman los domos más grandes. La separación entre los domos de vapor fue consistente con la teoría hidrodinámica, con la adición de que la separación entre domos se reduce a medida que evolucionan y crecen, debido a la curvatura de la superficie. ABSTRACT A numerical cooling analysis of a PBR fuel pebble, after an emergency scenario in which the nucleus disassembly is made and the pebbles are dropped into a water pool, transmitting heat by film boiling, involving convection and radiation to the fluid, is carried out in this Thesis. First, were performed validation tests comparing the numerical results with experimental works available for three different geometries, which allowed the selection of numerical models and schemes with better precision and lower computational cost. Once identified the numerical methodology, all validation tests were widely satisfactory, finding very good agreement with experimental works in average heat flux. During these validation tests were achieved numerically characterize some important parameters in film boiling with which there are certain levels of uncertainty, such as the coupling factor between convection and radiation, and the correction factor of the latent heat of vaporization. The thermal analysis of pebble cooling by film boiling shows that despite its decay heat, cooling occurs, with pebble surface temperature descending from an oscillatory manner, due to the instability of the vapor film. However, the temperature of this surface has a good uniformity, noting that the best and worst refrigerated area is located at the top of the pebble. The formation of multiple vapor domes at different circumferential positions is observed, which cause that the hottest area of the surface was located where biggest vapor domes were formed. The separation between vapor domes was consistent with the hydrodynamic theory, with the addition that the separation is reduced as the vapor dome evolves and grows, due to the surface curvature.

Heat transfer from molten materials to liquids

An apparatus was designed and constructed which enabled material to be melted and heated to a maximum temperature of 1000C and then flooded with a pre-heated liquid. A series of experiments to investigate the thermal interaction between molten metals (aluminium, lead and tin) and sub-cooled water were conducted. The cooling rates of the molten materials under conditions of flooding were measured with a high speed-thermocouple and recorded with a transient recorder. A simplified model for calculating heat fluxes and metal surface temperatures was developed and used. Experimental results yielded boiling heat transfer in the transition film and stable film regions of the classic boiling curve. Maximum and minimum heat fluxes were observed at nucleate boiling crisis and the Leidenfrost point respectively. Results indicate that heat transfer from molten metals to sub-cooled water is a function of temperature and coolant depth and not a direct function of the physical properties of the metals. Heat transfer in the unstable transition film boiling region suggests that boiling dynamics in this region where a stationary molten metal is under pool boiling conditions at atmospheric pressure would not initiate a fuel-coolant interaction. Low heat fluxes around the Leidenfrost point would provide efficient fuel-coolant decoupling by a stable vapour blanket to enable coarse mixing of the fuel and coolant to occur without appreciable loss of thermal energy from the fuel. The research was conducted by Gareph Boxley and was submitted for the degree of PhD at the University of Aston in Birmingham in 1980.

DIRECT NUMERICAL SIMULATION OF INCOMPRESSIBLE MULTIPHASE FLOW WITH PHASE CHANGE

Phase change problems arise in many practical applications such as air-conditioning and refrigeration, thermal energy storage systems and thermal management of electronic devices. The physical phenomenon in such applications are complex and are often difficult to be studied in detail with the help of only experimental techniques. The efforts to improve computational techniques for analyzing two-phase flow problems with phase change are therefore gaining momentum. The development of numerical methods for multiphase flow has been motivated generally by the need to account more accurately for (a) large topological changes such as phase breakup and merging, (b) sharp representation of the interface and its discontinuous properties and (c) accurate and mass conserving motion of the interface. In addition to these considerations, numerical simulation of multiphase flow with phase change introduces additional challenges related to discontinuities in the velocity and the temperature fields. Moreover, the velocity field is no longer divergence free. For phase change problems, the focus of developmental efforts has thus been on numerically attaining a proper conservation of energy across the interface in addition to the accurate treatment of fluxes of mass and momentum conservation as well as the associated interface advection. Among the initial efforts related to the simulation of bubble growth in film boiling applications the work in \cite{Welch1995} was based on the interface tracking method using a moving unstructured mesh. That study considered moderate interfacial deformations. A similar problem was subsequently studied using moving, boundary fitted grids \cite{Son1997}, again for regimes of relatively small topological changes. A hybrid interface tracking method with a moving interface grid overlapping a static Eulerian grid was developed \cite{Juric1998} for the computation of a range of phase change problems including, three-dimensional film boiling \cite{esmaeeli2004computations}, multimode two-dimensional pool boiling \cite{Esmaeeli2004} and film boiling on horizontal cylinders \cite{Esmaeeli2004a}. The handling of interface merging and pinch off however remains a challenge with methods that explicitly track the interface. As large topological changes are crucial for phase change problems, attention has turned in recent years to front capturing methods utilizing implicit interfaces that are more effective in treating complex interface deformations. The VOF (Volume of Fluid) method was adopted in \cite{Welch2000} to simulate the one-dimensional Stefan problem and the two-dimensional film boiling problem. The approach employed a specific model for mass transfer across the interface involving a mass source term within cells containing the interface. This VOF based approach was further coupled with the level set method in \cite{Son1998}, employing a smeared-out Heaviside function to avoid the numerical instability related to the source term. The coupled level set, volume of fluid method and the diffused interface approach was used for film boiling with water and R134a at the near critical pressure condition \cite{Tomar2005}. The effect of superheat and saturation pressure on the frequency of bubble formation were analyzed with this approach. The work in \cite{Gibou2007} used the ghost fluid and the level set methods for phase change simulations. A similar approach was adopted in \cite{Son2008} to study various boiling problems including three-dimensional film boiling on a horizontal cylinder, nucleate boiling in microcavity \cite{lee2010numerical} and flow boiling in a finned microchannel \cite{lee2012direct}. The work in \cite{tanguy2007level} also used the ghost fluid method and proposed an improved algorithm based on enforcing continuity and divergence-free condition for the extended velocity field. The work in \cite{sato2013sharp} employed a multiphase model based on volume fraction with interface sharpening scheme and derived a phase change model based on local interface area and mass flux. Among the front capturing methods, sharp interface methods have been found to be particularly effective both for implementing sharp jumps and for resolving the interfacial velocity field. However, sharp velocity jumps render the solution susceptible to erroneous oscillations in pressure and also lead to spurious interface velocities. To implement phase change, the work in \cite{Hardt2008} employed point mass source terms derived from a physical basis for the evaporating mass flux. To avoid numerical instability, the authors smeared the mass source by solving a pseudo time-step diffusion equation. This measure however led to mass conservation issues due to non-symmetric integration over the distributed mass source region. The problem of spurious pressure oscillations related to point mass sources was also investigated by \cite{Schlottke2008}. Although their method is based on the VOF, the large pressure peaks associated with sharp mass source was observed to be similar to that for the interface tracking method. Such spurious fluctuation in pressure are essentially undesirable because the effect is globally transmitted in incompressible flow. Hence, the pressure field formation due to phase change need to be implemented with greater accuracy than is reported in current literature. The accuracy of interface advection in the presence of interfacial mass flux (mass flux conservation) has been discussed in \cite{tanguy2007level,tanguy2014benchmarks}. The authors found that the method of extending one phase velocity to entire domain suggested by Nguyen et al. in \cite{nguyen2001boundary} suffers from a lack of mass flux conservation when the density difference is high. To improve the solution, the authors impose a divergence-free condition for the extended velocity field by solving a constant coefficient Poisson equation. The approach has shown good results with enclosed bubble or droplet but is not general for more complex flow and requires additional solution of the linear system of equations. In current thesis, an improved approach that addresses both the numerical oscillation of pressure and the spurious interface velocity field is presented by featuring (i) continuous velocity and density fields within a thin interfacial region and (ii) temporal velocity correction steps to avoid unphysical pressure source term. Also I propose a general (iii) mass flux projection correction for improved mass flux conservation. The pressure and the temperature gradient jump condition are treated sharply. A series of one-dimensional and two-dimensional problems are solved to verify the performance of the new algorithm. Two-dimensional and cylindrical film boiling problems are also demonstrated and show good qualitative agreement with the experimental observations and heat transfer correlations. Finally, a study on Taylor bubble flow with heat transfer and phase change in a small vertical tube in axisymmetric coordinates is carried out using the new multiphase, phase change method.

Experimental Study on Subcooled Pool Boiling in Microgravity Utilizing

Effect of channel surface wettability and temperature gradients on the boiling flow pattern in a single microchannel

The objective of this paper is to investigate the effects of channel surface wettability and temperature gradients on the boiling flow pattern in a single microchannel. The test section consists of a bottom silicon substrate bonded with a top glass cover. Three consecutive parts of an inlet fluid plenum, a central microchannel and an outlet fluid plenum were etched in the silicon substrate. The central microchannel had a width of 800 mu m and a depth of 30 mu m. Acetone liquid was used as the working fluid. High outlet vapor qualities were dealt with here. The flow pattern consists of a fluid triangle (shrinkage of the liquid films) and a connected long liquid rivulet, which is generated in the central microchannel in the timescale of milliseconds. The peculiar flow pattern is formed due to the following reasons: (1) the liquid rivulet tends to have a large contact area with the top hydrophilic channel surface of the glass cover, but a smaller contact area with the bottom silicon hydrophobic surface. (2) The temperature gradient in the chip width direction at the top channel surface of the glass cover not only causes the shrinkage of the liquid films in the central microchannel upstream, but also attracts the liquid rivulet populated near the microchannel centerline. (3) The zigzag pattern is formed due to the competition between the evaporation momentum forces at the vapor-liquid interfaces and the force due to the Marangoni effect. The former causes the rivulet to deviate from the channel centerline and the latter draws the rivulet toward the channel centerline. (4) The temperature gradient along the flow direction in the central microchannel downstream causes the breakup of the rivulet to form isolated droplets there. (5) Liquid stripes inside the upstream fluid triangle were caused by the small capillary number of the liquid film, at which the large surface tension force relative to the viscous force tends to populate the liquid film locally on the top glass cover surface.

Uniform mems chip temperatures in the nucleate boiling heat transfer region by selecting suitable, medium boiling number range

The not only lower but also uniform MEMS chip temperatures can he reached by selecting suitable boiling number range that ensures the nucleate boiling heat transfer. In this article, boiling heat transfer experiments in 10 silicon triangular microchannels with the hydraulic diameter of 55.4 mu m were performed using acetone as the working fluid, having the inlet liquid temperatures of 24-40 degrees C, mass fluxes of 96-360 kg/m(2)s, heat fluxes of 140-420 kW/m(2), and exit vapor mass qualities of 0.28-0.70. The above data range correspond to the boiling number from 1.574 x 10(-3) to 3.219 x 10(-3) and ensure the perfect nucleate boiling heat transfer region, providing a very uniform chip temperature distribution in both streamline and transverse directions. The boiling heat transfer coefficients determined by the infrared radiator image system were found to he dependent on the heat Axes only, not dependent on the mass Axes and the vapor mass qualities covering the above data range. The high-speed flow visualization shows that the periodic flow patterns take place inside the microchannel in the time scale of milliseconds, consisting of liquid refilling stage, bubble nucleation, growth and coalescence stage, and transient liquid film evaporation stage in a full cycle. The paired or triplet bubble nucleation sites can occur in the microchannel corners anywhere along the flow direction, accounting for the nucleate boiling heat transfer mode. The periodic boiling process is similar to a series of bubble nucleation, growth, and departure followed by the liquid refilling in a single cavity for the pool boiling situation. The chip temperature difference across the whole two-phase area is found to he small in a couple of degrees, providing a better thermal management scheme for the high heat flux electronic components. Chen's [11 widely accepted correlation for macrochannels and Bao et al.'s [21 correlation obtained in a copper capillary tube with the inside diameter of 1.95 mm using R11 and HCFC123 as working fluids can predict the present experimental data with accepted accuracy. Other correlations fail to predict the correct heat transfer coefficient trends. New heat transfer correlations are also recommended.