Multiscale enhancement of refrigerant falling film boiling by combining commercially enhanced tubes with nanostructures

Multiscale surface structures offer the opportunity to combine the heat transfer enhancement provided by microscale structures with the dryout benefits provided by some nanostructures, which is particularly attractive for falling film evaporators, who have to prevent dryout to ensure high heat transfer coefficients can be maintained. In this study commercially produced plain, low-finned and 3D enhanced commercially produced tubes were tested uncoated as well as coated with fibrous nanostructures that induce wicking on the surface to investigate the opportunity that multiscale enhancements might offer falling film boiling evaporators. Single tubes were heated internally by water and tested in the horizontal position with refrigerant R-134a drizzled over the outside of the tube surface at saturation temperatures of 5 and 25 degrees C, heat fluxes from 20 to 100 kW/m2 and film Reynolds numbers of up to 2000. The tubes tested were a roughened plain tube, a low-finned Gewa-KS tube and two different 3D enhanced tubes, an Gewa-B5 and an Turbo EHPII, that have networks of re-entrant cavities. The uncoated 3D enhanced tubes achieved the highest heat transfer coefficients, outperforming a roughened plain tube by up to 500 %. The uncoated low-finned tube had heat transfer coefficients that were up to 140 % higher than the roughened plain tube, despite having only an 80 % larger surface area, thought to be due to bubbles sliding down the channels between the fins, increasing the surface area of the bubbles in contact with the surface and thus allowing for increased microlayer evaporation. The application of the copper oxide coating benefitted the low-finned tube, with heat transfer enhancement of up to 60 %, possibly due to liquid wicked underneath the sliding bubbles and onto the fin tips. However, the nanocoating largely decreased the heat transfer of the roughened plain tube and the 3D enhanced tubes, thought to be due flooding of nucleation sites on the roughened tube and interference with the hydraulics of the reentrant cavity network on the surface of the 3D enhanced surfaces. The low-finned tube also benefitted the most from the falling film boiling heat transfer mode compared to previous pool boiling results, with heat transfer increased by up to 80 and 460 % for the uncoated and coated low-finned tube respectively, again likely due to the bubbles sliding in the fin channels under falling film conditions. The Gewa-B5 tubes had the best dryout performance, followed by the Turbo EHPII tubes and then the lowfinned Gewa-KS tube. The open pore structure of the Gewa-B5 likely aided it in dryout prevention, while the fins of the Gewa-KS are thought to have prevented lateral fluid distribution and thus worsen dryout. The dryout performance of the tubes we not markedly improved by the nanocoating, highlighting the difficulty in improving wettability on high wetting low surface tensions fluids such as refrigerants. Microscale enhancements were thus shown to have significant influence on dryout performance, while nanoscale enhancements had little effect in this study.