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1
enhanced, On the other hand, nucleate boiling can also be boundary layer, etc.) due to the existence of the fins. This
suppressed due to larger shear stresses near the wall [37]. assumption needs to be validated with experimental data.
Therefore, a smooth tube-based boiling correlation with the The existence of fins may significantly suppress nucleate
form boiling. The physics behind this phenomenon needs to be
αTP,boil = Fun (α nb , αcb ) (1) understood. However, nucleate boiling may not significantly
affect heat transfer when the flow Reynolds number is large,
can be modified to Robertson and Lovegrove [39] measured the boiling of R11 on
(α )
TP ,boil Fin = Fun ( Snbαnb , Ecbαcb ) (2) a serrated fin and Kandlikar [37] suggests S NB = 0.77 for it.
for boiling in plate-fin heat exchangers. Here, α TP ,boil is the In this work, we also assume this value.
2
⎧⎪0.079 Re−D1/4 for Re D ≤ 104 Table 4 Flow Conditions for Evaporator Test
f Blasius = ⎨ −1/5
(9) Cold Fluid R22
⎪⎩0.046 Re D for Re D > 104
Inlet Temperature: Tinlet = 279.6 K
Substituting (α sh )Fin and (α gra )Fin into Eqn. (4), we can Inlet Pressure: Pinlet = 0.611 × 10 Pa
6
obtain the modified condensation correlations for condensation Inlet Quality: xinlet = 0.2
in a compact plate-fin heat exchanger as:
(
(αTP,cond )Fin = Fun (α gra )Fin , (α sh )Fin )
Mass Flux: G = 99.5 kg/(m ⋅ s)
2
. (10)
Outlet Temperature: Toutlet ≈ 286.5 K
Outlet Pressure: Poutlet = 0.575 × 10 Pa
6
PROBLEM DESCRIPTION
Outlet Quality: xinlet = 1.0 (super-heating)
Hot Fluid Water
Inlet Temperature: Tinlet = 296 K
3
jMB ( Re) = 0.6522 Re −0.5403α −0.1541δ 0.1499γ −0.0678 ⎛ 2α ⎞
TP ,η ( t + l ) h
(11) tanh ⎜ ⎟
( )
0.1
× 1 + 5.269 × 10−5 Re1.34α 0.504δ 0.456γ −1.055 ⎜ λs tl 2 ⎟
ηF = ⎝ ⎠ (23)
f MB ( Re) = 9.6243Re−0.7422α −0.1856δ 0.3053γ −0.2659 2α f ( t + l ) h
(12)
( ) λs
0.1
× 1 + 7.699 ×10−8 Re4.429α 0.92δ 3.767 γ 0.236 tl 2
⎛ dP ⎞ ⎛ dP ⎞
( X tt )Fin = ⎜ ⎟ ⎜ ⎟ , (17)
⎝ dL ⎠l , FIN ⎝ dL ⎠ g , FIN
⎛ dP ⎞ G2
( ) (1 − x ) ,
2
⎜ ⎟ = 2 f Re (18)
ρl Dh
MB l
⎝ dL ⎠l ,Fin
⎛ dP ⎞ G2 2
⎜ ⎟
⎝ dL ⎠ g ,Fin
= 2 f MB ( Re g ) ρ g Dh
x , (19)
Figure 3. Illustration of fluid segments discretized
where along flow path
GDh (1 − x )
Rel = , (20)
µl The modified boiling and condensation models have been
implemented in the Thermal Analysis Software, INSTED. In
GDh x
Re g = . (21) this program, the flow passages are divided into small sections
µg (Fig. 3). The calculation tracks the flow from the inlet to the
The mean temperature difference between the fin surfaces and outlet of a fluid stream as the fluid goes through the passage.
saturated stream can be estimated as η F ΔTsat . The mean heat For instance, for every section along the cold fluid passage,
there is an exchange of heat with the hot fluid. However, to
transfer coefficient across the overall heat transfer area can be exchange the heat between the streams, the temperature of the
calculated as [37] fluid in the other stream must be determined. This can only be
αTP,η = ⎡⎣αTP, P + αTP, F ( AF / AP )ηF ⎤⎦ / (1 + AF / AP ) (22) done when the equations are solved on the segments of the
other stream. Therefore, an iterative scheme is needed to solve
where AF is the fin surface area, AP is the prime surface area the both streams. The procedure called “Incremental Method”
(heat transfer area not covered by fins), α TP , P is calculated is implemented and summarized in Fig. 4. Details of the
numerical procedure can be found in our previous work [42,
from boiling/condensation models by using ΔTsat as the 46].
By discretizing the flow path into sections, the local heat
driving temperature difference for phase change, and α TP , F is
transfer coefficient can be calculated by Eqn. (2) for boiling or
calculated from two phase models by using η F ΔTsat as the Eqn. (8) for condensation. Also, to account for the large
variations in thermos-physical properties, NIST’s REFPROP
driving temperature difference for phase change. The fin
database has been integrated into the INSTED program.
efficiency for the serrated fin is calculated by
4
Kandlikar [5], Liu and Winterton [6], and Steiner and Taborek
[7]. It can be seen that the modified models provide more
accurate results compared to the original models. The MAREs
of the modified models are around 20%, which is acceptable
considering the possible errors coming from the original single
phase correlations. Therefore, Eqn. (3) seems to give a good
estimation of ECB in this case. Note that these models appear to
over-predict the two-phase heat transfer coefficient
when x > 0.6 , which is due to the fact that the assumption made
in Eqn. (3) becomes invalid when the fluid approaches the
gaseous state (quality approaching 1).
Similarly, the calculated results for the 15 modified
condensation correlations are shown in Fig.6, together with the
results from the original models and Yara’s experimental data.
The mean absolute errors (MARE) of these models are also
given in Table 2. For this calculation, as stated in Yara’s paper,
the condensation is gravity-controlled. It can be observed that
the “stratified-flow only” model (Jaster-Kosky [19]), “gravity +
shear” (Fujii [22], Haraguchi [21], and Yu [23]) models, and
“multi-regime” models (Dobson [25], Thome [28], Cavallini
[27, 29], Shah [30]) gives relatively smaller errors compared
with “annular flow only” models (Kosky and Staub [17],
Cavallini and Zechin [18], Shah [20], Moser [24]). Since the
condensation is gravity-controlled, the scaling factor proposed
in Eqn. (8) needs to be assessed. To validate the proposed
scaling factor on the shear terms in these models, the numerical
results are again compared with the experimental data, where
shear- controlled condensation dominates. In Fig. 6, we can see
that, with the exception of the models by Carpenter and
Colburn [16] and Webb [26], most of the original condensation
models can still provide fair agreement with the experimental
data, suggesting that the assumption made on the gravity-
controlled condensation in the proposed models - where we
assume that the effects of the fin surface on the gravity-
controlled condensation is negligible - is probably reasonable.
CONCLUSION
Figure 4 Flow chart of the incremental iteration In this study, 30 boiling and condensation correlations
procedure in INSTED Thermal Analysis Software developed for smooth tubes have been modified and tested for
[42] use in a compact plate-fin heat exchanger. The test results show
that the modified correlations can provide acceptable results.
RESULTS & DISSCUSSION However, more experimental data is needed to further validate
The boiling calculation results are shown in Fig.5 where the proposed models.
the flow quality ( x ) versus the heat transfer coefficient ( αTP )
curves are plotted for all the 15 modified boiling correlations. REFERENCES
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7
α
NOMENCLATURE St = Stanton number, ≡
Gc p
A = area, m2 T = temperature, K
q" T+ = dimensionless temperature
Bo = boiling number, ≡
hlg G ΔTsat = temperature difference between wall
cp = specific heat, J/ ( kg ⋅ K ) and saturate fluid temperature, K
0.5 ⎧T − T for boiling
⎡1 − x ⎤ ⎛ ρ g ⎞
0.8
≡ ⎨ w sat
Co = convection number, ≡ ⎢ ⎜ ⎟ ⎩Tsat − Tw for condensation
⎣ x ⎥⎦ ⎝ ρl ⎠
Dh = hydraulic diameter, m G 2 Dh
We = Webber number, ≡
E = augmentaion factor ρσ
f = friction factor x = quality
X = Martinelli parameter
G2
Fr = Froude number, ≡ 2 Y = Chishom parameter
ρ gDh
α = heat transfer coefficient, W/ ( m2 ⋅ K )
g = gravitational constant, m / ( kg ⋅ s 3 2
) ηF = fin efficiency
G = mass flux, kg/ ( m2 ⋅ s )
µ = viscosity, kg/ ( m ⋅ s )
g ρl ( ρl − ρ g ) Dh3 ρ = density, kg/m3
Gal = Galileo number, ≡
µl2 λ = thermal conductivity, W/ ( m ⋅ K )
hlg = latent heat, J/kg σ = surface tension coefficient, N/m
j = Colburn factor, ≡ StPr 2/3 φ = two phase frictional multiplier
c p ,l (Tsat − Tw ) εg = void fraction
Jal = Jakob number, ≡
hlg τw = wall shear stress, N/m 2
M = molecular weight, g/mol A = area, m2
MAE = mean absolute error A = area, m2
N conf = confinement number,
0.5 Subscript
⎡ σ ⎤
≡⎢ ⎥ / Dh an = annular
⎢⎣ g ( ρl − ρ g ) ⎥⎦ cb = convective boiling
αD cr = critical state
Nu = Nusselt number, ≡ f = fin
λ g = vapor
P = pressure, Pa
go = with all fluid as vapor
Pred = reduced pressure, Pa, ≡ P / Pcr
gra = gravity controlled
ΔPsat = change of saturated fluid pressure l = liquid
due to ΔTsat , Pa lo = with all fluid as liquid
Pr = Prandtal number nb = nucleate boiling
Q = heat transfer rate, W sat = saturation
sh = shear controlled
q" = heat flux, W/m2
str = stratified
Re = Reynolds number TP = two phase flow
S = suppression factor w = wall
8
Table 1 Selected boiling correlations
9
Table 2 Selected condensation correlations
10
35000 Gungor & Winterton (1986) 35000
30000 Chen (1966) 30000 Shah (1982) Gungor & Winterton (1987) 30000 Kandlikar (1990)
30000 30000
25000 25000 25000
25000 25000
20000 20000 20000
α [W/m K]
α [W/m K]
α [W/m K]
α [W/m K]
α [W/m K]
20000
20000
2
2
15000 15000 15000
15000
15000
35000
35000
30000 Liu & Winterton (1991) Steiner & Taborek (1992) 30000 Kattan (1998) Koyama (1995) 30000 Rohsenow (1951)
30000
30000
25000 25000 25000
25000
25000
20000 20000 20000
α [W/m K]
α [W/m K]
α [W/m K]
α [W/m K]
α [W/m K]
20000 20000
2
2
15000 15000 15000
15000 15000
α [W/m K]
α [W/m K]
α [W/m K]
α [W/m K]
α [W/m K]
20000 20000 20000 20000 20000
2
2
2
15000 15000 15000 15000 15000
0 0 0 0 0
0 0.2 0.4 0.6 0.8 1 0 0.2 0.4 0.6 0.8 1 0 0.2 0.4 0.6 0.8 1 0 0.2 0.4 0.6 0.8 1 0 0.2 0.4 0.6 0.8 1
X X X X X
Figure 5. Numerical quality v.s. heat transfer coefficient plots for various boiling correlations with comparison of Yara’s experimental data.
11
Carpenter & Colburn (1951) Kosky & Staub (1971) Cavallini & Zecchin (1974) Jaster & Kosky (1976) Shah (1979)
20000 20000 20000 20000
15000
α [W/m K]
α [W/m K]
α [W/m K]
α [W/m K]
10000
2
2
10000 10000 10000 10000
5000
5000 5000 5000 5000
αexp αexp αexp αexp
αTP (modified) αTP (modified) αTP (modified) αexp αTP (modified)
αTP (original) αTP (original) αTP (original) αTP αTP (original)
0 0 0 0 0
1 0.8 0.6 0.4 0.2 0 1 0.8 0.6 0.4 0.2 0 1 0.8 0.6 0.4 0.2 0 1 0.8 0.6 0.4 0.2 0 1 0.8 0.6 0.4 0.2 0
X X X X X
20000
15000 15000 15000 15000
15000
α [W/m K]
α [W/m K]
α [W/m K]
α [W/m K]
α [W/m K]
2
2
10000 10000 10000 10000
10000
α [W/m K]
α [W/m K]
α [W/m K]
α [W/m K]
2
2
10000 10000 10000 10000 10000
Figure 6. Numerical quality v.s. heat transfer coefficient plots for various condensation correlations with comparison of Yara’s experimental data
12