Numerical Modeling of Annular Laminar Film Condensation in Circular and Non-Circular Micro-Channels under Normal and Micro-Gravity

A theoretical and numerical model to predict film condensation heat transfer in mini, micro and ultra micro-channels of different internal shapes is presented in this thesis. The model is based on a finite volume formulation of the Navier-Stokes and energy equations and it includes the contributions of the unsteady terms, surface tension, axial shear stresses, gravitational forces and wall thermal conduction. Notably, interphase mass transfer and near-to-wall effects (disjoining pressure) are also included. This model has been validated versus various benchmark cases and versus published experimental results from three different laboratories, predicting micro-channel heat transfer data with an average error of 20 % or better. The conjugate heat transfer problem arising from the coupling between the thin film fluid dynamics, the heat transfer in the condensing fluid and the heat conduction in the channel wall has been studied and analyzed. The work has focused on the effects of three external wall boundary conditions: a uniform wall temperature, a non uniform wall heat flux and single-phase convective cooling. The thermal axial and peripheral conduction occurring in the wall of the channel can affect the behavior of the condensate film, not only because it redistributes the heat, but also because the annular laminar film condensation process is dependent on the local saturation to wall temperature difference. When moving from mini to micro and ultra-micro channels, the results shows that the axial conduction effects can become very important in the prediction of the wall temperature profile and they can not be ignored. Under these conditions, the overall performances of the heat exchanger become dependent not only on the fluid properties and the operative conditions but also on the geometry and wall material. Results obtained for steady state conditions are presented for circular, elliptical and flattened shape cross sections for R-134a and ammonia, for hydraulic diameters between 10 µm and 3 mm. Microscale condensation finds applications in heat pipes and compact heat exchangers for electronic equipment or spacecraft thermal control, in automotive condensers, in residential air conditioning and in refrigeration applications: the influence of the steady or unsteady gravitational field and of the inertia forces on the flow field and consequently on the heat transfer performances is investigated allowing the model to be applied as a design and optimization tool for enhanced heat exchangers.

Numerical Modeling of the Conjugate Heat Transfer Problem for Annular Laminar Film Condensation in Microchannels

Stefano Nebuloni, John Richard Thome

This paper presents numerical simulations of annular laminar film condensation heat transfer in microchannels of different internal shapes. The model, which is based on a finite volume formulation of the Navier-Stokes and energy equations for the liquid phase only, importantly accounts for the effects of axial and peripheral wall conduction and nonuniform heat flux not included in other models so far in the literature. The contributions of the surface tension, axial shear stresses, and gravitational forces are included. This model has so far been validated versus various benchmark cases and versus experimental data available in literature, predicting microchannel heat transfer data with an average error of 20% or better. It is well known that the thinning of the condensate film induced by surface tension due to gravity forces and shape of the surface, also known as the "Gregorig" effect, has a strong consequence on the local heat transfer coefficient in condensation. Thus, the present model accounts for these effects on the heat transfer and pressure drop for a wide variety of geometrical shapes, sizes, wall materials, and working fluid properties. In this paper, the conjugate heat transfer problem arising from the coupling between the thin film fluid dynamics, the heat transfer in the condensing fluid, and the heat conduction in the channel wall has been studied. In particular, the work has focused on three external channel wall boundary conditions: a uniform wall temperature, a nonuniform wall heat flux, and single-phase convective cooling are presented. As the scale of the problem is reduced, i.e., when moving from mini- to microchannels, the results show that the axial conduction effects can become very important in the prediction of the wall temperature profile and the magnitude of the heat transfer coefficient and its distribution along the channel. [DOI: 10.1115/1.4005712]

2012

Numerical modeling of laminar annular film condensation for different channel shapes

Stefano Nebuloni, John Richard Thome

This paper presents a theoretical and numerical model to predict film condensation heat transfer in mini and micro-channels of different internal shapes. The model is based on a finite volume formulation of the Navier-Stokes and energy equations and it includes the contributions of the unsteady terms, surface tension, axial shear stresses, gravitational forces and wall conduction. Notably, interphase mass transfer and near-to-wall effects (disjoining pressure) are also included. Dimensional analysis and characteristic numbers of the process are proposed and simulation results are shown both in dimensionless and dimensional representations. Isothermal, iso-heat flux and variable heat flux external wall boundary conditions have been implemented and their effects on the distribution of the heat flux are shown and compared. The instantaneous local and perimeter-averaged heat transfer coefficients, the liquid condensate film thickness distribution, the cross sectional void fraction and the mean vapor quality can be obtained for different channel shapes. Results obtained for steady state conditions are presented for circular, elliptical (with different eccentricities), flattened (with different aspect ratios) and flower shape cross sections for R-134a and ammonia, for hydraulic diameters between 10 pm and 3 mm. A time dependent simulation with variable heat flux is presented for a copper channel having a length of 4 cm and a rectangular cross section with a hydraulic diameter of 133 mu m and an aspect ratio of 2, showing the importance of axial conduction at this length scale. The model has been validated versus various benchmark cases and versus experimental data available in literature. (C) 2010 Elsevier Ltd. All rights reserved.

Elsevier2010

Experimental investigation of heat transfer and flow characteristics in various geometries of 2-pass internal cooling passages of gas turbine airfoils

Denis Chanteloup

An experimental investigation of the flow and heat transfer characteristics in internal coolant passages of gas turbine airfoils has been conducted. The PIV method was employed for the flow measurements. A stereoscopic PIV system was used and automated. The stereoscopic method allowed measuring the three velocity components in measurement planes. The system was capable of measuring 100 planes in each configuration. Each measurement plane was composed of 30*30 measurement points. The transient liquid crystal technique was adopted for the heat transfer measurements. Full surface Nusselt number distributions were obtained on all the five outer walls of the test models. The transient TLC technique was adapted in large-scale models of internal cooling channels. The gas temperature evolution in location and time was taken into account in the data processing. CFD simulations have been performed in the measured passage configurations. For the calculations, the unstructured flow solver FLUENT/UNS was employed. A test rig was designed and constructed for the experiments to meet the requirements of the intended investigation. For the present investigation, the test section was a large-scale model of a two-pass coolant passage with a sharp 180° bend. Four different coolant passage configurations were tested: A passage with 45° ribs (baseline configuration). A passage similar to the baseline configuration with extraction holes simulating film-cooling extraction. A passage with film-cooling extraction and a turning vane in the bend region. A passage with ribs 50% bigger than in the baseline configuration. This passage also had a turn region back wall angled at 30° to the incoming flow. The four configurations were tested at three Reynolds numbers (25,000, 50,000, 70,000 based on the hydraulic diameter). The configurations with extraction were tested at three extractions (30%, 40%, 50% of the inlet massflow). For the first time, the PIV and TLC techniques were employed simultaneously for a detailed investigation of the turbulent flow and heat transfer characteristics within internal coolant passages connected with 180° turns. The following conclusions can be drawn: 3D-streamlines were extracted from the flow measurements in the various cooling channels. The streamlines underlined the strong influence of both the ribs and the bend geometry on the creation of the secondary flow motion in the channels. The secondary flow motion dominates the heat transfer in the entire cooling channel. In the fully developed region, the rib-induced vortex governs the heat transfer distribution on the ribbed walls behind the ribs, and also on the sidewalls. In the bend region, the bend corner flow cells (with low streamwise velocity motion) deviate the bend incoming flow. They act as if the sharp bend geometry was modified. This geometry modification is very dependant on the studied configuration. The resulting heat transfer distribution is thus strongly configuration dependant. The regions of high heat transfer in the channels have been linked with high impinging flow regions. High gradients of mean impinging velocity components near the walls induce high heat transfer on the wall. In these regions, the Nusselt number showed a good correlation with the Reynolds normal stress corresponding to the impinging velocity. The configurations with extractions have the best thermal performances at all the tested Reynolds numbers. The variation of the extraction ratio does not modify substantially the thermal performances. CFD tools has benefited from the tremendous progress of computing power. 3D simulations of internal cooling configurations are now possible. CFD predictions have gained accuracy in such highly 3D flow problems. The predictions compared well with the measurements, with worst discrepancies of 25%.

EPFL2002

Numerical Modeling of the Conjugate Heat Transfer Problem for Annular Laminar Film Condensation in Microchannels

Stefano Nebuloni, John Richard Thome

2012

Experimental investigation of heat transfer and flow characteristics in various geometries of 2-pass internal cooling passages of gas turbine airfoils

Denis Chanteloup

EPFL2002