Steps towards the development of an experimentally verified simulation of pool nucleate boiling on a silicon wafer with artificial sites

Nucleate boiling is a very effective heat transfer cooling process, used in numerous industrial applications. Despite intensive research over decades, a reliable model of nucleate pool boiling is still not available. This paper presents a numerical and experimental investigation of nucleate boiling from artificial nucleation sites. The numerical investigation described in the first section of the paper is carried out by a hybrid mechanistic numerical code first developed at the University of Ljubljana to simulate the temperature field in a heated stainless steel plate with a large number of nucleation sites during pool boiling of water at atmospheric pressure. It is now being redeveloped to interpret experiments on pool boiling at artificial sites on a silicon plate and as a design tool to investigate different arrangements of sites to achieve high heat fluxes. The code combines full simulation of the temperature field in the solid wall with simplified models or correlations for processes in the liquid-vapour region. The current capabilities and limitations of the code are reviewed and improvements are discussed. Examples are given of the removal of computational constraints on the activation of sites in close proximity and improvements to the bubble growth model. Preliminary simulations are presented to compare the wall conditions to be used in the experiments on silicon at Edinburgh University with the conditions in current experiments on thin metal foils at Ljubljana. An experimental rig for boiling experiments with artificial cavities on a 0.38 mm thick silicon wafer immersed in FC-72, developed at Edinburgh University, is described in the second part of the paper

Simulation and experimental investigation of pool boiling on a silicon wafer with artificial nucleation sites

This paper reports progress on a project to develop a design tool for large arrays of nucleation sites at specified locations to achieve high rates of cooling by pool boiling. The tool will be based on an improved version of a hybrid simulation, in which the 3-D temperature field in the wall is solved numerically, along with simple sub-models for bubble-driven heat transfer that require experimental calibration. Improvements to the computer code and progress with the experiments are reported briefly. The paper focuses on the development of a sub-model for the lateral coalescence of bubbles, which is shown to cause irregularity in the bubble production by a regular array of nucleation sites

Boiling of water and FC-72 in microchannels enhanced with novel features

A microchannel test section comprised of parallel square microchannels with a 25 × 25 μm and 50 × 50 μm cross section was manufactured. Boiling of perfluorinated dielectric fluid FC-72 and water in microchannels was studied. Troublesome occurrences associated with flow boiling in microchannels were reduced or eliminated with inlet/outlet restrictors, inlet/outlet manifolds and potential nucleation cavities incorporated in the array of microchannels. The gradual reduction of channel cross section in the manifolds ensured a uniform distribution of the working fluid among the microchannels. The flow restrictors provided a higher upstream pressure drop in comparison with the downstream pressure drop which favors vapor flow in the downstream direction and consequentially suppresses the vapor backflow present in flow boiling. The superheat of the microchannel wall necessary for the onset of boiling was decreased significantly with the incorporation of properly sized artificial cavities. Experimental results confirmed the benefits of the etched features, as there was (i) an even working fluid distribution (ii) without dominating backflows of vapor (iii) at a low temperature of the onset of boiling. Bubble growths as well as other events in the microchannels were visualized with a high-speed imaging system which captured images at over 87,000 frames per second. Results exhibit boiling hysteresis dependence of the working fluid and its mass flux through the microchannels. The temperature of the onset of boiling is highly dependent on the working fluid, microchannel size and its roughness

Effect of nucleation cavities on enhanced boiling heat transfer in microchannels

Boiling instabilities, high temperatures of the onset of boiling (ONB), and early transition to dryout are some of the insufficiently resolved issues of flow boiling in microchannels. This article addresses the flow boiling challenges with the incorporation of flow restrictors to reduce the boiling instabilities and hinder vapor backflows. In addition, the temperature of the ONB was lowered and the heat transfer coefficient was increased during boiling with the fabrication of potential nucleation cavities in the microchannel walls and bottom. Experiments were conducted with degassed double-distilled water in arrays of microchannels with the hydraulic diameter ranging from 25 to 80 µm, whereas the nucleation cavities characteristic sizes varied from 2 to 12 µm. The temperatures of the ONB were up to 35 K lower in the microchannel array with properly sized nucleation cavities compared to arrays of microchannels, in which the etched nucleation cavities were less suitable. The combined effect of fabricated nucleation cavities and interconnected microchannels increased the heat transfer coefficient from three to 10 times depending on the size of the etched nucleation cavities and the transferred heat flux in the microchannel arrays

Heat transfer enhancement of self-rewetting aqueous n-butanol solutions boiling in microchannels

Boiling experiments of pure water, aqueous n-butanol solutions and pure butanol were conducted in arrays of parallel microchannels with a cross-section of 25 × 25 μm and 50 × 50 μm. The introduction of 2% and 6% n-butanol solutions into microchannels with the mass fluxes ranging from 83 kg/m2 s to 208 kg/m2 s demonstrated an enhanced heat transfer during boiling compared to pure water and pure butanol. Both concentrations of butanol lowered the maximum temperature measured during boiling in the microchannel test section for approximately 10 K and 30 K compared to pure water and pure butanol, respectively. High-speed visualization, measurements of the contact angles and analysis of the surface roughness indicated that enhanced heat transfer originates from the improved wettability of the butanol solutions during boiling in microchannels, which is directly related to the positive surface tension gradient and the Marangoni effect. The self-rewetting property of the butanol solutions stimulated the formation of a well pronounced annular flow, enhanced the heat transfer and substantially lowered the temperatures measured in the microchannels during boiling

Product identification in industrial batch fermentation using a variable forgetting factor

For reliable operation and the optimization of production, industrial fermentation processes require appropriate tools for monitoring the process in real time. This work presents the structure and operation of a soft sensor for the on-line monitoring of biomass and product concentration during salinomycin and bacitracin fermentation in an industrial, 80-m3 batch reactor; moreover it provides a tool for evaluation of batch production verified in industrial application. The process estimation algorithm consists of decoupled growth and product models, which ensures an unbiased convergence of the estimator and the robustness of the model. The production of secondary metabolites is described with a non-structured model upgraded with a variable forgetting factor that demonstrated a successful estimation of the non-measured parameters and states of this highly interactive and interlinked system with complex dynamics. The possibility of using various input signals in product identification yields independent soft sensors. This serves to improve the reliability of the predictions, mutual sensor control and enables the detection of irregularities in the fermentation process before the broth becomes useless

Mechanistic models for pool nucleate boiling heat transfer: input and validation

Correlations for nucleate boiling heat transfer should be improved, or in the long term possibly be replaced, by the development of mechanistic simulations that include the non-uniform spacing and variable characteristics of the nucleation sites and non-linear interactions between the sites. This paper discusses the interactions that should be included in simulations and some lessons from a first attempt to validate a particular simulation against experimental spatio-temporal data for wall temperature. Input data for nucleation site positions and characteristics are a particular problem and the prospects for obtaining this data from measurements that are independent of boiling are discussed

Comparison of a mechanistic model for nucleate boiling with experimental spatio-temporal data

Mechanistic numerical simulations have been developed for pool nucleate boiling involving large groups of nucleation sites that are non-uniformly distributed spatially and have different activation superheats. The simulations model the temperature field in the heated wall accurately and use approximations for events in the liquid–vapour space. This paper describes the first attempt to compare the numerical simulations with spatio-temporal experimental data at a similar level of detail. The experimental data were obtained during pool boiling of water at atmospheric pressure on a horizontal, electrically heated stainless steel plate 0.13 mm thick. They consist of wall temperature fields measured on the back of the plate by liquid crystal thermography at a sampling rate of 200 Hz over a period of 30 s. Methods of image analysis have been developed to deduce the time, position, nucleation superheat and size of the cooled area for every bubble nucleation event during this period. The paper discusses the methodology of using some of the experimental data as input for the simulations and the remainder for validation. Because of the high-dimensional dynamics and possibly chaotic nature of nucleate boiling, the validation must be based on statistical properties over a large area and a long period. This preliminary study is restricted to a single heat flux

Effects of controlled nucleation on freeze-drying lactose and mannitol aqueous solutions

The lyophilization of lactose and mannitol aqueous solutions was investigated with an emphasis on analyzing the effects of controlled nucleation, temperature of nucleation, and pore size distribution on the freeze-drying process. The experimental procedure involved the depressurization technique of controlled nucleation, in-vial temperature measurements as well as measurements of the chamber pressure, which allowed the analysis of the product batch, loaded in the laboratory lyophilizator. The average pore enlargement was 93 and 58% with the incorporation of the controlled nucleation step in the lyophilization of 6 wt% lactose and 6 wt% mannitol solutions, respectively. Consequently, the primary drying times were lowered from 450 to 500 min in both cases. The pore sizes were determined to be as important as the solid material itself in the scope of the sublimation rates. Namely, the average equivalent diameter of the pores was larger in the dried mannitol cake compared to the lactose cake. However, despite the higher porosity of the dried mannitol cake, the end of the sublimation in the primary drying step was observed approximately 500 min earlier during the lyophilization of the lactose solution with the same initial concentration as the mannitol solution in a comparable freeze-drying protocol. In addition, an increase in mannitol concentration from 3 to 12 wt% was found to substantially extend the time required for the sublimation phase of the lyophilization