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Review
a r t i c l e
i n f o
Article history:
Received 16 July 2013
Received in revised form 28 October 2013
Accepted 29 October 2013
Available online 9 November 2013
Keywords:
Two-phase ow
Microchannels
Flow instability
Heat transfer
Evaporation
Numerical simulations
a b s t r a c t
A survey of the most recent work aimed at physically characterizing local heat transfer in ow boiling in
microchannels is presented. This includes recent experimental work, new ow boiling prediction methods, and numerical simulations of microchannel slug ows with evaporation. Some signicant developments in the measurement techniques provide simultaneous ow visualizations and measurements of
2D temperature elds of multi-microchannel evaporators. In particular, information on inlet micro-orices has been gained as well as better ways to reduce such heat transfer and pressure drop data for very
high resolution data (10,000 pixels at rate of 60 Hz). First of all, ow patterns are seen to have a significant inuence on the heat transfer trends in microchannels (just like in macrochannels), and thus need
to be accounted by visualization during experiments and during modeling. A clear distinction between
steady, unsteady, well- and maldistributed ows needs to be made to avoid any confusion when presenting and comparing the heat transfer coefcient trends. In reducing the raw data to local heat transfer
coefcients, the calculated values of several terms involved in the heat transfer coefcient determination
are inuenced by the data reduction procedure, especially the way to deduce the local saturation pressures/temperatures, and may lead to conicting trends and errors approaching 100% in local heat transfer
coefcients if done inappropriately. In addition to experiments, two-phase CFD simulations are emerging
as a tenable tool to investigate the local heat transfer mechanisms, especially those details not accessible
experimentally. In particular, a new prediction method based on numerical simulation results captures
the heat transfer in the recirculating liquid ow between elongated bubbles. Thus, it is shown here that
targeted computations can provide valuable insights on the local ow structures and heat transfer mechanisms, and thus be used to improve the mechanistic boiling heat transfer prediction methods.
2013 Elsevier Ltd. All rights reserved.
Contents
1.
2.
3.
4.
5.
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
State-of-the-art of microscale two-phase flow boiling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.1.
Microchannel flow boiling heat transfer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.2.
Infra-red camera measurements applied to microchannels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Numerical simulations of two-phase flow boiling in microchannels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.1.
Numerical models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.2.
Literature review . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Discussion on the most recent experimental and numerical results of heat transfer studies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.1.
Contribution of numerical simulations to the heat transfer modeling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.2.
Heat transfer coefficient data reduction in multi-microchannels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.3.
Stable and unstable two-phase heat transfer coefficients . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Conclusions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
85
85
85
88
89
89
90
91
91
93
95
99
99
1. Introduction
A noticeable global tendency towards miniaturization driven by
the micro-electronics industry is bringing ever greater attention to
multi-microchannel two-phase ow evaporation as the most
advantageous cooling process, utilizing the latent heat of evaporation to extract the heat in an energy efcient manner. As a result of
the enhanced thermal performance compared to other processes,
better axial temperature uniformity (Agostini et al., 2008b), reduced coolant ow rates, and thus smaller pumping powers (Agostini et al., 2007) are obtained. Therefore, two-phase ow cooling
provides an excellent opportunity to continue the progress relative
to Moores law (Moore, 1965) associated with a tremendous challenge of removing the continuously increasing heat uxes dissipated by modern CPUs. The large amount of experimental work,
theory and prediction methods have been reviewed in the past
few years by Thome (2004, 2006), Cheng et al. (2008), Thome
and Consolini (2010) and Baldassari and Marengo (2013). Consequently, the present review has a narrow scope to look at some
new emerging issues regarding experimentation and the targeted
use of numerical simulations to gain local, transient insight into
the two-phase evaporation process and improvement of its heat
transfer models.
Numerous micro-evaporators have been tested over the past
few years. Their reported heat transfer performances, quantied
in terms of local heat transfer coefcients, depend on the data
reduction methods and assumptions each study used. Several aspects, such as determination of the local uid saturation temperature, edge heat losses and heat spreading effects, and ow stability,
need to be more carefully taken into account when comparing and
modeling heat transfer coefcient results. Obviously, only the values calculated in the same manner, when merged together, will
bring adequate conclusions on microchannel cooling capabilities.
Moreover, the experimental techniques for measurements have
some technical limitations due to the small length and time scales
involved in ow boiling within microchannels. For instance, the
time response for thermocouples in point-wise temperature measurements is usually larger than the characteristic time of the
investigated phenomena, whilst experiments with Micro Particle
Image Velocimetry (MicroPIV) still remain a challenging task at
these high ow velocities.
On the other hand, the recent advances on multiphase Computational Fluid Dynamics (CFD) techniques, together with the
increasing processing power of computers, are making numerical
simulations an ever more powerful and reliable tool to provide
new and detailed insights into the local hydrodynamics and thermal features of ow boiling in microchannels. The accuracy of
the gasliquid interface tracking and modeling of interfacial effects
is of primary importance for microscale-aimed computational
methods, since the interface topology plays a fundamental role in
ows within microdevices. Volume Of Fluid (VOF) (Hirt and Nichols, 1981) and Level Set (LS) (Sussman et al., 1994) methods are
indeed the most widely used algorithms to model interfacial ows,
due to their accuracy, robustness and easiness of implementation.
In fact, the cited algorithms only add a color function equation
(to identify each phase) to the single-phase ow equation set,
which includes mass, momentum and energy equations, that are
then solved in a xed computational grid. However, it is important
to remark that while numerical simulations provide an advanced
tool to investigate two-phase ows which may also anticipate
experimental ndings, the development of such computational
methods requires detailed experimental measurements to validate
their new algorithms.
The present paper is organized as follows: rst the most recent
experimental ndings on microscale two-phase ows are reviewed
85
in Section 2, then Section 3 outlines the latest advances in multiphase numerical simulations in microchannels, next Section 4 discusses their mutual contribution and related issues of data
reduction, stable and unstable ow, and hydrodynamics to the heat
transfer coefcient trends, and nally Section 5 summarizes the
main conclusions of this work.
86
0:1 1:1
q
Bo
xCBAF 425 v
ql
Co0:5
r
where Bo q=Ghlv is the boiling number and Co r= g DqD2h
Fig. 1. Heat transfer coefcient trend for ow boiling of R236fa in a silicon multimicrochannel evaporator with orices at the inlet of each channel restricting the
ow by 50% (creating some ashed vapor to seed the evaporation process) at the
channel mass ux Gch 2299 kg m2 s1 and the base heat ux qb 48:6 W cm2
(Szczukiewicz et al., 2012b, 2013b). Flow visualization images were recorded by
Revellin (2005) in a sight glass at the exit of a single stainless steel tube of 0.79 mm
diameter.
Fig. 1). Afterwards, the heat transfer coefcient rises in the AF regime, when all the bubbles have coalesced and the liquid has
formed an annular ring with a continuous vapor core in the middle
of the channel. It is an effect of convective boiling across the thinning liquid lm. Therefore, the trend of the heat transfer coefcient
strongly depends on the ow pattern and the ow transitions between them. These transitions are preliminary controlled by the
rate of bubble coalescence and they are commonly dened by
the vapor quality x, e.g. Agostini et al. (2008a), Revellin et al.
(2008) and Ong and Thome (2011a).
It is worthwhile mentioning that the three-zone model of
Thome et al. (2004) predicts the heat transfer coefcient to decrease in the CB regime but to increase in the IB regime (two zones
without the third dryout intermittent zone). Recently, Costa-Patry
and Thome (2012, 2013) have presented a new ow pattern-based
prediction method for heat transfer coefcient in microchannels.
2200
2
17.4 W cm
2
20.8 W cm
2
25.1 W cm
28.5 W cm2
32.6 W cm2
2
36.3 W cm
40.2 W cm2
44.1 W cm2
2
48.1 W cm
1800
1600
1400
ch
[kg m2 s1]
2000
1200
1000
800
0
0.02
0.04
0.06
0.08
0.1
0.12
0.14
0.16
0.18
x []
Fig. 2. Vapor quality at the minimum heat transfer coefcient calculated based on
Eq. (1) for the two-phase ow of R1234ze(E) in the test section with the inlet
restrictions of expansion ratio ein;rest WW ch 2 and the base heat ux varying from
in;rest
17.4 to 48:1 W cm2 . The graph was prepared using the experimental data of
Szczukiewicz (2012) considering only stable ows, namely the single-phase ow
followed by two-phase ow without backow and the ashing two-phase ow
without backow operating regimes.
is the connement number, with hlv being the latent heat of vaporization, Dq the difference between the liquid and vapor densities
(respectively ql and qv ), r the surface tension coefcient, g the
gravity acceleration, and Dh the hydraulic diameter. According to
Eq. (1), which predicts the vapor quality at the minimum heat
transfer coefcient (see Fig. 2), the transition is a function of the liquid-to-vapor density ratio, as well as the mass ux G and the heat
ux q, giving results similar to those of Ong and Thome (2011a).
Some modications to the original heat transfer models of Thome
et al. (2004) for elongated bubble ow regime and the annular ow
model of Cioncolini and Thome (2011) were implemented to improve their performance in predicting heat transfer. For instance,
the three-zone model of Thome et al. (2004) was modied by setting the minimum lm thickness to the measured wall roughness
since the roughness breaks the liquid lm. This has been already
proposed in the previous studies of Agostini et al. (2008c) in a silicon test section, Ong and Thome (2011b) in three stainless steel
microtubes, and Vakili-Farahani et al. (2012) in an aluminum multiport tube, while the study of Costa-Patry et al. (2012a) included
both silicon and copper test sections. Table 1 gives more details
on the geometrical specications of the test sections and refrigerants they have investigated.
The above heat transfer prediction method of Costa-Patry and
Thome (2012, 2013) along with the Chen (1966)-like heat transfer
method of Bertsch et al. (2009) seem to be the most accurate ones
available today (Costa-Patry and Thome, 2012, 2013). Fig. 3(a)
demonstrates the heat transfer coefcient trends for both of these
methods in comparison to the experimental results of Szczukiewicz (2012). Firstly, it is seen that the Bertsch et al. (2009) model,
however, does not capture the increasing trend of heat transfer at
higher vapor qualities (corresponding to the AF regime). While, the
prediction method of Costa-Patry and Thome (2012, 2013) predicts
both the trend and the heat transfer coefcients well. This is especially true at low and high values of vapor quality and the location
of the local minimum of the heat transfer coefcient, given by Eq.
(1), representing the CB AF ow transition. The largest discrepancies between the predicted and the experimental values are noticeable at this transition (churn ow), which remains a region of
uncertainty in the multi-microchannel heat transfer studies, and
is very complex to mechanistically model. Together with the tests
listed in Table 1 and those in the recent work of Szczukiewicz et al.
(2012b, 2013b) shown in Fig. 1, their ow pattern based method so
far works for square and rectangular channels with aspect ratios
from about 1 to 10, for single circular channels, for multiport tubes,
and for numerous refrigerants.
Harirchian and Garimella (2012) also used the three-zone model of Thome et al. (2004) (with some modications) as the basis to
predict their experimental data (Harirchian and Garimella, 2008,
2009a,b, 2010) for 7 different microchannel heat sinks. The channel
locations where the ow transformed from bubbly to slug and consequently to annular ow were determined, and then the pressure
drop for each regime occurring along the channel was separately
calculated. They also proposed a ow regime-based method that
provided reliable results, but only for their one uid (FC-77) at
one saturation temperature, and hence only one set of physical
properties; thus its use with any other uid is an extrapolation.
87
Test section
Surface roughness
Test uid
Agostini et al.
(2008d)
Ong and Thome
(2011b)
170 nm
Vakili-Farahani
et al. (2012,
2013)
Dh 1:4 mm
R245fa and
R236fa
R245fa,
R236fa, and
R134a
R245fa,
R1234ze(E),
and R134a
Costa-Patry and
Thome (2012,
2013)
450 nm
67 to 90 nm
See above
See above
R245fa,
R1234ze(E),
and R134a
R245fa and
R236fa
See above
(a)
x 10
x 10
15
2.5
Tran et al. (1996)
w [W m2 K ]
w [W m
K ]
Experimental
2
1.5
Experimental
CostaPatry and Thome (2012)
Bertsch et al. (2009)
0.5
Yu et al. (2002)
10
0.05
0.1
0.15
0.2
0.25
0.3
(b)
0
0
x []
0.05
0.1
0.15
0.2
0.25
0.3
x []
x 10
w [W m2 K1]
2.5
1.5
1
Experimental
New buffer for CostaPatry and Thome (2012)
Bertsch et al. (2009)
0.5
0.05
0.1
0.15
0.2
0.25
0.3
x []
Fig. 3. Experimental two-phase ow heat transfer coefcients of R236fa in the
100 100 lm2 multi-microchannel with ein;rest 4 for Gch 525 kg m2 s1 and
qw 155:3 kW m2 compared to the prediction method of Bertsch et al. (2009), (a)
original model of Costa-Patry and Thome (2012, 2013), and (b) the latter with the
new vapor quality buffer xbuffer 2xCBAF . Figure extracted from Szczukiewicz
(2012).
They did not unfortunately present any graph with trend lines of
the heat transfer coefcient data versus local vapor quality, nor
the trends of their predictions. Hence, the method of Harirchian
and Garimella (2012) was not compared with the experimental
0:3
ql
qv
0:27
0:4
2
ql
qv
0:2
3
88
(a)
Created based
on the flow
observation
from the top
(b)
(c)
(d)
Flow direction
Fig. 5. (a) Two-phase ow operational map for R236fa in the micro-evaporator
with the 50 lm-wide, 100 lm-deep, and 100 lm-long inlet restrictions ein;rest 2,
where:
single-phase ow,
single-phase ow followed by two-phase ow
with backow,
(b) single-phase ow followed by two-phase without backow
(desirable operating regime),
two-phase ow with backow triggered by
bubbles formed in the ow loop before the test section, and
(c) ashing twophase ow without backow (the most desirable operating regime). (b) Photograph
of the experimental ow boiling test facility with the optical system. This
operational map and the photo of the test rig were extracted from Szczukiewicz
et al. (2013a). The thermal maps (c) and (d) were recorded for the two-phase ow of
R245fa in the test section of ein;rest 2 (Szczukiewicz, 2012).
0.08 K at 30 C. Patil and Narayanan (2005, 2006) utilized IR thermography to obtain spatially-resolved temperature measurements
in a single silicon, uniformly heated microchannel of the same
width as Hardt et al. (2007), but having a higher aspect ratio. Both
the wall and near-wall uid temperatures (here water) were measured, depending on the opacity of the channel wall. The IR camera
calibration was done implementing intensity maps during water
ow at the temperature of 23.5 C, although this does not explain
measurements at other temperatures. An IR camera was also used
(together with a high-speed ow visualization camera) by Barber
et al. (2009, 2011) to study ow boiling instabilities of n-pentane
in a single rectangular microchannel having a hydraulic diameter
of 727 lm under uniform heating. The accuracy of their IR temperatures was reported to be 1 C.
Recently, Szczukiewicz et al. (2012a,b, 2013b) introduced a new
in situ pixel by pixel technique to calibrate the raw infra-red image
signals with an accuracy of 0.2 C, and thus converting them into
accurate two-dimensional temperature elds of 10,000 pixels over
the heated surface of the silicon micro-evaporator. The test facility
and the test sections were designed such that simultaneous twophase ow patterns (through a transparent Pyrex cover plate) and
temperature visualizations in 67 microchannels of 100 100 lm2
cross-sectional areas were possible. To this aim, they used a highspeed video camera placed above the test section and a high-speed
infra-red (IR) camera below, as shown in Fig. 5(b). Their results for
R245fa, R236fa, and R1234ze(E) at a variety of the channel mass
ux Gch and the base heat ux qb were categorized into 8 different
two-phase ow operating regimes, among which 2 examples are
illustrated in Fig. 5, where T IR is a temperature measured at the base
of the test section, y indicates an axis perpendicular to the ow
direction, while z denotes the distance form the channel entrance.
This description applies also to the other thermal maps in this paper. The ashing two-phase ow without backow operating regime, shown in Fig. 5(d), was identied as the most desirable one,
since it provided the best spatio-temporal temperature and ow
uniformities. Moreover, several new two-phase ow operational
maps were developed for the two-phase ow of refrigerants
R245fa, R236fa, and R1234ze(E) owing in the test sections with inlet restrictions (used for ow stabilization, as suggested by Kosar
et al. (2006); Agostini et al. (2008c); Park et al. (2009)) and without
any inlet restrictions. An example of such an operational map for
R236fa owing in the test section with the inlet restrictions of the
expansion ratio of ein;rest 2 is presented in Fig. 5(a). From an engineering stand-point of view, these operational maps are very
important for specifying the most advantageous operating conditions, at which the ow is always going to be stable for eventual actual electronics cooling applications. More details on the two-phase
ow operational study of refrigerants in multi-microchannel
evaporators for future high-performance 3D-ICs can be found in
Szczukiewicz (2012) and Szczukiewicz et al. (2013a).
89
q ql qv ql I
_
rum
qv
ql
dS
where u denotes the uid velocity. The term at the r.h.s. represents
_ is the interphase
the mass source due to the evaporation, where m
mass transfer and dS is a delta function which is non-zero only at
the interface and its expression depends on the specic multiphase
algorithm adopted.
The momentum equation for Newtonian uids in laminar ow,
appropriate for microchannels, takes the following form:
@qu
r qu u rp r lru ruT qg
@t
rjndS
with t being the time, p the pressure, q and l the single-uid density and viscosity to be computed as it is shown in Eq. (4), and g the
gravity vector. The last term on the r.h.s. represents the surface tension force for a constant surface tension coefcient, where j and n
identify the local interface curvature and unit normal vector. The
interface topology is not available explicitly in VOF and LS methods,
but it can be derived by means of the color function eld as
n rc=jrcj and j r n as originally proposed by Brackbill
et al. (1992). However, the computation of the interface curvature
by means of derivatives of the color function is known to be of poor
accuracy for VOF methods as pointed out by Cummins et al. (2005),
thus generating errors in the estimation of the surface tension force.
Since the surface tension is a dominant force in the microscale, the
accuracy of its calculation is fundamental to obtain reliable numerical results. Hence, it is preferable that VOF schemes include specic
algorithms for the reconstruction of the interface topology such as
the parabolic tting of Renardy and Renardy (2002), the Height
Function method (Cummins et al., 2005), or coupled LS and VOF
schemes (CLSVOF) (Sussman and Puckett, 2000).
The energy equation to be solved is given by:
@qcp T
r qcp uT r krT s
@t
_ lv cp;v cp;l TdS
: ru mh
90
where T indicates the temperature, cp and k are respectively the single-uid specic heat at constant pressure and thermal conductivity, while s represents the shear stress tensor. The second term on
the r.h.s. represents the viscous heating which may become important for very small channel sizes (negligible for the sizes considered
here), while the third term implements the enthalpy sink due to
evaporation, that of the vapor created and of the liquid that disappears. Usually, the temperature variations are sufciently small
such that the physical properties of the phases are considered constant. The set of the ow equations is then completed by the transport equation for the color function:
_
m
@c
u rc dS
@t
q
which is used to update the position of the interface and then the
mixture uid properties as time elapses.
To complete the formulation, an evaporation model to express
_ as a function of the local temperathe interphase mass transfer m
ture and pressure is necessary. If microscale effects on mass transfer are neglected, the interface is assumed to be at the saturation
temperature, such that the temperature eld is continuous across
the interface, and the mass transfer can be computed as
_ krT n=hlv (Mukherjee and Kandlikar, 2005; Mukherjee,
m
2009; Mukherjee et al., 2011; Lee et al., 2012; Suh et al., 2008).
However, as the scale of the problem is reduced, interphase resistance and disjoining and capillary pressures tend to create a discontinuity in the temperature and pressure elds across the
interface, thus generating an interfacial resistance to mass transfer
which decreases the evaporation rate. In this direction, Schrage
(1953) derived a relationship to express the interphase mass transfer as a function of the local temperatures and pressures of the liquid and gas phases at the interface, while Wang et al. (2007)
showed that the following linearized expression is a good
approximation:
_ C T T i T v C p pl pv
m
91
effect is not negligible when modeling the heat transfer in the liquid lm region by assuming one-dimensional heat conduction.
By adding a transient term to the original three-zone models formulation (which was developed for much thinner liquid lms, on
the order of 1/100 of the channel diameter), the time-law of the
heat transfer coefcient given by CFD simulations was predicted
satisfactorily. This inuence is more signicant for shorter bubbles
since the thermal boundary layer development length then plays a
larger role; hence this effect is more important in the IB regime
where bubbles are still relatively short L < 2D but less so in the
CB regime where coalescence of bubbles results in mostly long
bubbles L > 5D.
With the aim of improving the modeling of the heat transfer in
the liquid slug zone of the three-zone model, consider two bubbles
owing and evaporating in sequence in a circular microchannel.
They were simulated using the numerical framework already discussed above by Magnini et al. (2013a), taking advantage of a 2D
axisymmetrical formulation to limit the computational time of
the simulations. For horizontally oriented channels, this is a valid
assumption provided that Co > 1, as observed experimentally by
Ong and Thome (2011a), and hence only working conditions
matching such criterion were chosen. The reliability of the solver
in modeling the ow of axisymmetrical elongated bubbles was assessed by a positive comparison of the liquid lm thickness
trapped between the bubbles and the wall in adiabatic conditions
with the Han and Shikazono (2009) correlation, the latter based on
their measurements with a highly accurate oscillating microscope
technique. The validation of the numerical results in ow boiling
conditions were also proven by comparing the position of the nose
of the growing bubble against time with the theoretical model derived by Consolini and Thome (2010) for the ow of coalescing
bubbles in microchannels. Fig. 6 shows the computational and theoretical results for three different operating uids, namely R113,
R245fa and R134a, under similar operating conditions. The comparison is quite positive, where the increasing underestimations
of the model at the highest time steps are due to the assumption
that the bubble grows only by absorbing the wall heat ux, while
in the numerical simulations the bubble also grows because it receives the sensible heat of the superheated liquid by evaporation
across the nose of the bubble.
12
10
4
R113
R245fa
2
R134a
10
12
14
16
Time [ms]
Fig. 6. Positions of the bubble nose against time in ow boiling conditions, given by
simulations (solid lines) and Consolini and Thome (2010) model (dashed lines).
Simulation conditions: D = 0.5 mm, q 20 kW m2 ; G 600 kg m2 s1 (R113,
R245fa) and 500 kg m2 s1 (R134a), T sat 50 C (R113, R245fa) and 31 C (R134a).
92
at
q
T w t T sat
10
@2T
@T
qcp
@y2
@t
k
@T
as T T sat
@y
k
D
liquid
slug
leading
bubble
trailing
bubble
liquid
3000
2500
2000
1500
Simulation
Model
1000
15
20
25
30
35
40
45
Time [ms]
Fig. 7. Heat transfer coefcient after 21 heated diameters given by the simulation
of two bubbles owing in the microchannel and by the proposed analytical model
for the heat transfer. The black vertical lines identify the transit of the bubbles nose
and rear.
12
11
13
where Pe is the Peclet number of the liquid within the slug and Ls is
the length of the liquid slug. Note that, in Eq. (12), the recirculating
ow region is assumed to be at the saturation temperature. The initial temperature prole for the liquid slug region is obtained by the
model itself, as the temperature prole at the end of the previous
liquid lm region. The so-dened ow problem allows an analytical
expression for the heat transfer coefcient in the liquid slug region
to be obtained, which is then coupled with the solution presented
by Magnini et al. (2013a) for the liquid lm zone. The prediction given by this updated model is plotted in red in Fig. 7 and it estimates
the heat transfer trends and magnitude in satisfactory agreement
with the results of the computations. This model can be developed
further to decrease the overestimation observed in Fig. 7 as shown
in Magnini et al. (2013b), and to be made fully stand-alone by
means of correlations available in the literature to estimate those
parameters (e.g. thin liquid lm thickness, wall-adherent liquid
layer thickness, etc.) provided here by the numerical simulation results. Hence, this case study provides a good example of how
numerical two-phase simulations can be used to identify new aspects of the heat transfer process in microchannel slug ow and
provide the input to the development of new theoretical models.
93
(a)
Nondimensional radial
position
25
26
27
28
29
30
31
32
33
34
(b)
liquid slug
region
l T =h s (TTs)
y
liquid film
region
recirculating zone
vapor bubble
T=Tsat
y
s
adherent film
liquid film
z
Fig. 8. (a) Streamlines of the velocity eld relative to the velocity of the nose of the trailing bubble, at t = 22.4 ms. The black lines identify the bubbles proles which are
superimposed to the streamlines plot. (b) Scheme of the decomposition of the ow eld within the microchannel adopted by the proposed two-zone boiling heat transfer
model for slug ow. Since d; ds
R, the radial coordinate is here replaced by the vertical coordinate y.
aw z
qw z
T w z T fl z
14
94
(a)
39
(a)
x 10
3D
linear
prorated
Tfl [ oC]
q ft [W m2]
37
35
1D
33
2
10
z [mm]
(b)
x 10
(b)
3.5
3
10
x 10
3.5
2.5
83%
2
1.5
1
[W m2 K1]
w
[W m2 K1]
z [mm]
2.5
2
1.5
1
linear
1D
homogeneous pch
0.5
0.5
prorated
3D
10
z [mm]
Fig. 9. (a) Prorated uid temperature (Szczukiewicz, 2012), and (b) local heat
transfer coefcient trends assuming linear, homogeneous, and prorated pressure
(and consequently uid saturation temperature) proles along the channel for
R236fa owing in the test section with ein;rest 4, Gch 1692 kg m2 s1 ,
qb 47:8 W cm2 for the experimental channel pressure drop of 46.3 kPa. Note
that in Fig. 9(b), as explained later in the text, the heat transfer coefcients affected
by edge effects are excluded.
temperature prole for determining the local heat transfer coefcients (Szczukiewicz, 2012). Fig. 9(b) highlights the important differences in the local heat transfer coefcients using three different
approaches: (i) assuming linear, (ii) homogeneous, and (iii) prorated pressure (and consequently saturation temperature) proles.
The homogeneous pressure drop model (taken here as an example)
overpredicts the values of the channel pressure drop and thus lowers the value of the local saturation temperature of the refrigerant
at the exit and the value of the local heat transfer coefcient, leading to a difference of 83% between the approaches (ii) and (iii) at
z = 9.5 mm for this test case. Furthermore, the linear pressure drop
assumption articially brings the local heat transfer coefcients to
lower values (except the inlet and the outlet temperatures which
are experimentally measured), which might severely affect the
heat transfer coefcients along the length by up to 10%, when comparing to the approach (iii), i.e. at the CB-AF ow transition. Therefore, the proration method for simulating the uid temperature is
recommended as the most appropriate one in order to provide the
most accurate estimation of the local heat transfer coefcient (future experimental studies should take note of this).
Turning now to another common data reduction procedure, the
conventional 1D heat conduction approach does not take into account the heat spreading towards the colder surrounding regions
that can be observed due to the strong variation in the local heat
transfer coefcient with vapor quality along the channel and at
0
0
0.05
0.1
0.15
0.2
x []
Fig. 10. Two-phase ow of R1234ze(E) in the test section with ein;rest 2 for
Gch 1705 kg m2 s1 and qb 32 W cm2 : (a) actual heat ux at the root of the
ns along the channel length qft , and (b) local wall heat transfer coefcients, aw ,
obtained using the 1D and 3D conduction schemes in function of x. Figure extracted
from Szczukiewicz (2012).
the boundaries. Costa-Patry (2011) noted that the lateral non-uniform heat ux distribution changes the local pressure drop and
evaporation rates. Consequently, the calculated values of the local
wall temperatures and heat uxes and local vapor qualities are
inuenced by the data reduction procedure. The heat spreading effects can be accounted for by using the pragmatic 3D thermal conduction scheme of Costa-Patry (2011), where the temperature and
heat ux values at the test sections base are found by spatially discretizing the 3D domain and then solving an energy balance for
each control volume (CV). Afterwards, assuming the external walls
of the silicon test section to be adiabatic, the various nodes are
linked with each other, such that: Q L n Q R n 1,
Q F n Q B n 1, and Q D n Q U n 1, where Q is the heat
ow rate and n is a natural number indicating the layers number.
The notations above are as follows: D for down (base for the rst
layer of CVs), U up, L left, R right, F front, and B back. This
procedure is quite fast and yields comparable results to a full 3D
heat conduction simulation.
Fig. 10 presents the comparison between the 1D and 3D heat
conduction schemes (Szczukiewicz, 2012), where the silicon wafer
was discretized in 100 100 (set to the pixels of the IR temperature measurements) 140 control volumes (and taking into account the thermal conductivity change with respect to
temperature). The biggest discrepancy is noticeable at the corners,
where the edge effects are most signicant and they were better
captured by the 3D heat conduction model. As can be seen, the rst
and the last 5 pixels of the IR array include edge effects, and thus
they are discarded. Moreover, the heat spreads towards the colder
surrounding regions (regions of higher heat transfer coefcients
and slope in T fl ), here at the inlet and the outlet, and the actual heat
ux in those zones is rst higher and then lower than that assumed
in 1D calculations. Therefore, the heat transfer coefcients determined assuming 1D conduction from the base of the silicon micro-evaporator to the root of the ns are underpredicted at the
inlet and the outlet of the channel, as demonstrated in Fig. 10(b),
where the local vapor quality is calculated with corresponding local heat ux prole of the 1D and 3D calculations. If the heat
spreading is not considered, the heat transfer coefcient is overpredicted at the local minimum, which corresponds to a ow transition. The present silicon test section has only a 0.28 mm base
thickness, but still exhibits some heat spreading, which will be
even more signicant for thicker micro-evaporators. Fig. 11 shows
an example of the local wall heat transfer coefcients of R236fa obtained through 1D and 3D heat conduction schemes at a wall heat
ux of qw 71 kW m2 and three different mass uxes, where for
instance for Gch 2099 kg m2 s1 at z = 9.5 mm the heat transfer
coefcient accounting for 3D heat spreading is 14% higher compared to 1D heat conduction scheme. Thus, 3D heat spreading
should be included in all future data reduction procedures in
experimental studies to obtain the most accurate results for the
values of aw and x, and thus the data trends. Since a real microevaporator cold plate is subject to heat spreading effects, it is
important that test data are reduced and then modeled in the same
manner as the actual application.
Fig. 12(a) illustrates the wall heat transfer coefcient, aw , obtained using 3D heat spreading in the silicon micro-evaporator of
Szczukiewicz (2012), plotted versus the longitudinal channel location, z, and compared to the corresponding ow pattern map transition (vertical blue line). The descending trend of aw at the
beginning of the channel (low vapor quality range) corresponds
to the coalescing bubble (CB) region, where the elongated bubbles
coalesce and the local intermittent dry-out patches are formed
(Thome et al., 2004). The local minimum of the heat transfer coefcient is well located by the coalescing bubble annular ow (CB
AF) transition of Costa-Patry and Thome (2012, 2013), computed
according to Eq. (1). Fig. 12(b) shows a video image of the ow
aligned with the graph at the top. The color changes along the
channel from almost black at the entrance (subcooled ow/bubbly
ow) to nearly white (transition region) and becomes gray at the
3.5
x 10
[W m
w
(a)
(b)
Fig. 12. The ashing two-phase ow without backow operating regime of R236fa
in the micro-evaporator with ein;rest 4 for Gch 2096 kg m2 s1 and
qb 47 W cm2 : (a) wall heat transfer coefcient, aw , and (b) video image of ow.
Figure extracted from Szczukiewicz (2012).
2.5
K ]
95
2
1.5
G = 911 kg m2 s1, 1D
ch
2 1
Gch = 911 kg m s , 3D
G = 1514 kg m2 s1, 1D
ch
2 1
Gch = 1514 kg m s , 3D
G = 2099 kg m2 s1, 1D
ch
2 1
Gch = 2099 kg m s , 3D
1
0.5
0
0
0.1
0.2
0.3
0.4
0.5
x []
Fig. 11. Two-phase wall heat transfer coefcient as a function of local vapor quality
for R236fa owing in the test section with the inlet restrictions of ein;rest 4 for
qw 171 kW m2 . The calculations of the local vapor quality here included the 3D
heat spreading effect.
Two-phase ow stability is the next important issue to be considered (but often ignored in the microchannel ow boiling literature), which needs to be addressed in any credible heat transfer
study, since its effect might signicantly change the heat transfer
coefcient trends and values with respect to the vapor quality, as
illustrated by a specic experimental comparison performed by
Consolini and Thome (2009). Figure 13(a) and (b) shows the twophase ow boiling of R245fa and the time-averaged temperature
distribution in the micro-evaporator without any inlet restrictions
(micro-orices). As expected, signicant ow instabilities, vapor
backow, and ow maldistribution occur, which are eventually
governed by the pressure drop in each individual channel, which
lead to high-amplitude and high-frequency temperature and pressure oscillations (see for instance Wu and Cheng (2003)). It is
worthwhile to mention that in such a situation, the assumption
of uniform mass ux in all the channels is invalid and it is not
96
(a)
(b) 10
IR
[ C]
54
52
y [mm]
50
6
48
46
44
2
42
40
2
10
z [mm]
(c)
TIR [oC]
(d)
54
10
y [mm]
50
OUTLET
Flow direction
No back flow
INLET
52
8
48
46
44
2
42
40
2
10
z [mm]
Fig. 13. Snapshots of the high-speed ow visualization and the time-averaged IR temperature maps of the test sections base provided by the two-phase ow boiling of
R245fa for Gch 2035 kg m2 s1 and qb 36:5 W cm2 : (a), (b) without any inlet restrictions, and (c), (d) with the 50 lm-wide, 100 lm-deep, and 100 lm-long inlet microorices (Szczukiewicz et al., 2012b; Szczukiewicz et al., 2013b). The ow is from left to right in all the presented images for both ow and temperature.
advised to be used to reduce the data for local heat transfer coefcients. This illustrates the necessity of developing new measurement techniques for determining the mass ux in each individual
channel within multi-microchannel test sections.
As demonstrated in Fig. 13(c), such undesired phenomena
might be prevented by using an inlet slit to create restrictions at
the entrance of each channel, which tend to stabilize the twophase ow (Agostini et al., 2008c). For the same reason, Park
et al. (2009) used inlet restrictions for each channel in their copper
test section. These restrictions and the channels in their case were
fabricated separately and then aligned within the multiple-microchannel element tested. Nonetheless, such a solution is not applicable for silicon chips, where the restrictions are generally
fabricated along with the channels, applying the same manufacturing process. Recently, Szczukiewicz et al. (2012b, 2013b), used
rectangular orices at the inlet of each channel (they were manufactured in one etching process together with the microchannels)
with expansion ratios varying from ein;rest 1:33 to 4. However,
they saw that the micro-orices of ein;rest 1:33 did not stabilize
the two-phase ow of R236fa within the range of the tested experimental conditions. Such geometries were also previously studied
by Peles and co-workers, i.e. Kosar et al. (2006), Schneider et al.
(2006, 2007), Kosar and Peles (2007).
Fig. 14 illustrates the two-phase ow and temperature patterns
of R236fa for three different micro-orices sizes tested by Szczukiewicz (2012) at the same experimental conditions. The channels
were 100 100 lm2 of cross-sectional area, while the expansion
ratio of the inlet restrictions was varied from 1.33 to 4. As can be
seen, the overall two-phase ow stability improves with increasing
the expansion ratio of the inlet restrictions. In Fig. 14(b), the test
sections base temperature appears to have medium values,
97
(a)
TIR [oC]
(b) 10
46
8
y [mm]
44
6
42
4
40
38
36
2
10
z [mm]
(c)
(d)
TIR [ C]
10
46
8
y [mm]
44
6
42
4
40
38
36
2
10
z [mm]
(e)
(f)
TIR [oC]
10
46
8
y [mm]
44
6
42
4
40
38
36
2
10
z [mm]
Fig. 14. Snapshots of the high-speed ow visualization and the time-averaged IR temperature maps of the test sections base provided by the two-phase ow boiling of
R236fa for Gch 1100 kg m2 s1 and qb 36 W cm2 : (a), (b) ein;rest 1:33, (c), (d) ein;rest 2, and (e), (f) ein;rest 4. The ow is from left to right in all the presented images for
both ow and temperature.
Table 2
Spatio-temporal average temperatures of the test sections base for
Gch 2094 kg m2 s1 of channel mass ux, the base heat ux, qb , ranging from 25
to 48 W cm2 and the expansion ratios of the inlet restrictions of ein;rest 2 and 4,
where DT T b;av e ein;rest 4 T b;av e ein;rest 2.
qb
W cm2
T b;av e ein;rest 2
C
T b;av e ein;rest 4
C
DT
K
25.0
29.0
32.6
36.6
40.0
44.4
48.0
42.6
43.5
44.3
45.3
46.1
47.0
47.6
45.2
46.0
46.8
47.3
48.1
48.9
49.5
2.6
2.5
2.5
2.0
2.0
1.9
1.9
In Fig. 15 at low vapor qualities, the descending trend of aw corresponds to the coalescing elongated bubble region, as predicted
by the three-zone model of Thome et al. (2004). In this zone, the
higher expansion ratio leads to a drop of the heat transfer coefcient, as explained previously. After reaching the local minimum,
which corresponds relatively well to the CB AF ow transition
of Costa-Patry and Thome (2012, 2013), the heat transfer increases
with increasing vapor quality. In the annular ow regime, the heat
transfer coefcient for the higher expansion ratio grows more signicantly. This can be ascribed to the instability of the vaporliquid interface triggered by the higher velocities associated with
the smaller restriction that gives a more irregular bubble interface,
thus enhancing the time-averaged heat transfer coefcient (Tibirica et al., 2012). In addition the perturbed interface promotes more
liquid to be entrained in the vapor core, which was shown by
Cioncolini and Thome (2011) to have a positive effect on the heat
transfer performance (of course as long as dryout is avoided).
98
x 10
[W m2 K1]
2.5
2
1.5
e
in,rest
in,rest
0.5
2 1
Gch = 2099 kg m
s , qb = 16.9 W cm
2.5
2
1.5
K ]
w [W m
x 10
3.5
3.5
=2
=4
1
0.5
0
0
0
0.05
0.1
0.15
0.2
0.25
0.05
0.1
0.15
0.25
0.3
Fig. 16. Two-phase wall heat transfer coefcient of R236fa in the micro-evaporator
with the inlet restrictions of the expansion ratio of ein;rest 4 as a function of local
vapor quality, where solid lines correspond to experimental results, while the
dashed ones represent the simulated (steady) values obtained using the ow
pattern-based heat transfer model of Costa-Patry and Thome (2012, 2013).
its whole lifetime in practical applications. To this aim, the temperature uctuations for a selected pixel of the IR cameras sensor array are assessed in Fig. 17. Note that the highest standard deviation
of the temperature uctuation, 0.82 K, is detected for the unstable
two-phase ow with backow developing into jet ow operating
regime (c), but as shown in Szczukiewicz (2012) it can be much
higher. On the other hand, the ashing two-phase ow without
backow, dened as the most optimum operating regime, provides
very stable ow with a temperature standard deviation of 0.04 K.
Additionally, the current analysis reveals that the frequency of the
temperature oscillations is about 2 to 6 Hz for unstable two-phase
ow (c). The frequency increases with mass and heat uxes (g, h),
simultaneously with decreasing the amplitude of the oscillations,
such that above a certain threshold for heat and mass ux the
oscillations disappear and the ow can be regarded as stable. The
60
55
(h)
(g)
50
Tb [oC]
Fig. 15. Two-phase wall heat transfer coefcient as a function of local vapor quality
for R236fa in the test section with the inlet restrictions of ein;rest 2 and 4 for
Gch 2081 kg m2 s1 and qw 173 kW m2 (stable two-phase ows).
0.2
x []
x []
(b)
45
(a)
(c)
(e)
(d)
(f)
40
35
30
0
10
20
30
40
50
t [s]
Fig. 17. Temporal temperature uctuations at the base of the silicon microevaporator of ein;rest 2: (a) single-phase ow in the entire test section with the
vapor bubbles appearing only at the manifolds outlet plenum, (b) single-phase ow
followed by two-phase ow with backow into the inlet header, (c) unstable twophase ow with backow developing into jet ow, (d) jet ow, (e) single-phase ow
followed by two-phase ow without backow, (f) two-phase ow with backow
triggered by bubbles formed in the ow loop before the test section, (g) ashing
two-phase ow (at exit of inlet micro-orices) with backow, and (h) ashing twophase ow without backow. Figure extracted from the Ph.D. thesis of Szczukiewicz
(2012).
2.8
x 10
z = 2 mm, ein,rest = 2
z = 2 mm, e
=4
in,rest
z = 5 mm, e
=2
in,rest
z = 5 mm, ein,rest = 4
z = 8 mm, e
=2
in,rest
z = 8 mm, ein,rest = 4
2.4
w [W m2 K ]
2.6
2.2
2
1.8
1.6
1.4
0
10
y [mm]
Fig. 18. Width-wise heat transfer coefcient proles for two-phase ows of R236fa
in ein;rest 2 (unsteady case) and ein;rest 4 (steady case) at the longitudinal channel
location of z 2, 5, and 8 mm for Gch 1292 kg m2 s1 and qb 43:2 W cm2 ,
considering an array of 90 90 IR temperatures.
99
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