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T.N. Dinh, Y.Z. Yang, J.P. Tu, R.R. Nourgaliev, and T.G. Theofanous
Center for Risk Studies and Safety, University of California, Santa Barbara
6740 Cortona Drive, Goleta CA 93117
Tel: 1-805-893-4942, Fax: 1-805-893-4927, Email: nam@engr.ucsb.edu
Abstract – This paper is concerned with fundamental issues in predicting the onset and pattern
formation in Rayleigh-Benard thermal convection in a fluid layer heated from below.
Theoretically, thermal convection has long been a challenging subject in physics because of the
complexity embedded in such unstably stratified flows. Practically, Rayleigh-Benard convection is
central to many technologies and situations. In particular, core melt progression in a hypothetical
severe accident in a nuclear reactor is governed by heat transfer (and therefore energy splitting)
in molten metal/oxide layers. In previous studies, we conducted large-scale experiments and
numerical simulations to quantify melt pool heat transfer models. In the present study, we
developed a novel experimental approach and used an advanced diagnostic method to obtain
first-of-a-kind thermometry data on transient natural convection heat transfer. The data are used
to assess whether and to what extent Navier-Stokes and energy equations and their numerical
methods are capable of preserving and correctly predicting complexity in thermal convection, i.e.
onset and pattern formation. Uncertainty of physical measurements and numerical solutions are
discussed.
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Proceedings of ICAPP ’04
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Paper 4241
computational studies. The challenge lies in the complexity II. EXPERIMENTAL STUDY
of natural convection flows, with various patterns
emerging from seemingly chaotic dynamics. It has been In order to study Rayleigh-Benard natural convection,
argued that the Navier-Stokes equations, added by the we use an infrared camera to obtain thermal images of the
energy conservation equation (convective heat transfer), is heated surface. The main idea is to characterize the onset
a proper model for natural convection flow. However, to and formation of patterns in unstably stratified flow. The
date, such Navier-Stokes equations-based models fail to experimental approach for natural convection study stems
reproduce flow patterns characteristic of Rayleigh-Benard from our own work developed under a NASA grant to
convection. Interestingly, while these models are used at investigate pool boiling. Uniform heat flux on the heated
relatively high Rayleigh number, they seem to be able to surface is achieved by passing a direct electrical current
produce heat transfer rates at the pool boundary in a through a 460nm-thin Titanium films vapor-deposited on
reasonable agreement with experimental data. The 130 µm borosilicate glass substrate. In this paper, two
predictability of heat transfer means that the mixing in the heaters “I” and “H” from the same manufacturing series
pool is predictable. This is contrasted with the failure of were used in experiments to assure that behaviors observed
the model to predict organized flow patterns even at much in the experiments are not heater-specific. The heaters’
lower Rayleigh numbers. In fact, in order to reproduce the surface as manufactured is fresh and examined by Atomic
structure in thermal convection, physicists use an order Force Microscopy and Electron Scanning Microscopy. For
equation, similar to Carl-Hillard equation for spinodal more details about the heater manufacturing and
decomposition (Bodenschatz et al, 2000; Oh and Ahler, characterization, see Theofanous et al, 2002. Because of
2003). The dilemma thus persists on whether and to what the high accuracy of the vapor deposition process used in
extent the Navier-Stokes-equations-based model provides microelectronics industry, the Titanium film is expected to
an adequate representation of the complex physics in be of high uniformity in thickness. Also, because of the
thermal convection. small thickness of the Titanium film and the glass
substrate, temperature on and heat removal from the heater
The objective of this paper, and the work presented surface reflect nearly in a characteristic time (ms)
therein, is to examine the ability of the Navier-Stokes significantly shorter than that of thermal convection
equations to capture the emergence of complex patterns in (second).
thermal convection, and explore factors of physical and
numerical nature that may have contributed to the II.A. Experimental Arrangement
deterioration of the model performance when compared to
experimental measurements. The experimental arrangement named BETA-NC
included a test section, a computerized power supply
Our approach in this work is integrated experimental system, an infrared camera and data acquisition system
and computational. The motivation for a new experimental (DAS). This system has been developed under a NASA
study is the lack of transient data that may reveal how grant to study boiling heat transfer and boiling crisis, and
complex flow structures emerge in thermal convection. reported in detail in Theofanous et al (2002). The infrared
Furthermore, previous velocimetry data were qualitative, camera is a high-speed (1 KHz) high-resolution (30 µm)
rather than quantitative, making it very difficult for direct thermometry system from Santa Barbara Focalplane (a
comparison between images and results of direct numerical Lockheed-Martin company). The camera is specially
simulation (DNS) by solving the Navier-Stokes and energy designed and calibrated to provide high-accurate thermal
equations. The focus in this work is therefore placed on the imaging of the heater surface of the Titanium film-glass
instability and onset of pattern formation. substrate assembly over the temperature range of interest.
Thermal images obtained at high speeds and resolutions
The paper is organized as follows. In section II, we are transferred to DAS for storage and post-test analysis.
describe a novel experimental approach to thermal The accuracy of temperature measurement is achieved
convection, and present data that were obtained on through a calibration using the camera and the actual
transient heatup, onset of thermal convection and thermal heater kept under fixed temperatures. Specifically, for the
cells. Section III is devoted to a numerical study, where temperature range experimented in this work (20-100oC),
numerical methods and results are shown, and compared to the accuracy is ±0.3K.
the experimental data of section II. The focus is to examine
the ability of a numerical model and method to capture the The power supply provides a current- and voltage-
onset of thermal convection and pattern formation. controlled power input to the Titanium film for Joule
Uncertainties, both experimental and numerical origins, are heating. A step-change heating scheme is used through the
discussed. Major findings from the analysis are BETA-NC test program. Temperature profile of the heater
summarized as concluding remarks in section IV. surface upon a sudden application of electric current over a
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Proceedings of ICAPP ’04
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Paper 4241
(heat-conduction) phase is used as an indicator of the Also, the fluid layer upper surface was kept as free in
uniformity of the applied heat flux. We will discuss results most tests. For comparison, a wall boundary condition was
of relevant tests and measurement shortly below. applied in selected test runs, and results of comparison
between non-slip and free upper surfaces did not reveal
The test section used is a rectangular glass vessel, any effect on the infrared thermal images of thermal
closed at the bottom by the heater element, it occupying convection onset and development. The free surface
the entire 27x40 mm2 cross section of the vessel (Figure condition is then chosen as the base test case shown in this
1). Special techniques allow gasket-free sealing and hence paper.
avoidance of contamination. Neither the vertical glass
walls nor the glass substrate are isolated in experiments Before proceeding further, it is worth noting that the
shown in this paper. The heat losses were estimated to be “classical” Rayleigh-Benard thermal convection is
insignificant to the onset and pattern formation phase characterized by the Rayleigh number defined as
studied in this paper.
gβ (Tbot − Ttop ) H 3
Ra =
αν
where H is height of fluid layer, m; Tbot and Ttop are
temperatures of the bottom and upper surfaces, α is
thermal diffusivity, m2/s, and ν is kinematic viscosity,
m2/s. In the BETA-NC experiments, temperatures on the
bottom and upper surfaces are not fixed. Since in this case,
q = cons, and H ~ (α t)1/2, we have
gβqαt 2
Ra q =
ν
It can be seen that the Rayleigh number, Raq, increases
with time.
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Proceedings of ICAPP ’04
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Paper 4241
rapid cooling, followed by a level-off. The onset occurred thermal boundary layer unstable due to the lower density
in about 4 seconds after the power start. of the heated fluid (thermal boundary layer grows to 1mm
in the conduction phase, 4 s). The physical picture is
similar, in principle, to Rayleigh instability when lighter
fluid is accelerated into heavy one. The distinction, and
difficulty, here is in the absence of any interface and sharp
change in fluid density. It is also not straightforward to
apply the instability criterion for classical Rayleigh-Benard
thermal convection, in which a conductive fluid layer is
motionless and under a temperature gradient between its
upper and bottom walls (Ra = 1200…2400 ~ RaCR =1700).
In interpreting the BETA-NC experimental runs, the term
“conduction” is conditional as the fluid expends during the
heatup phase. The fluid velocity is upward, and we define
the onset of thermal convection when the colder fluid
descends toward the heater and initiate cooling.
∂ρU (1)
+ ∇ ⋅ ( ρU ) = 0
∂t
∂ρU (2)
+ ∇ ⋅ ( ρU ⊗ U ) = ρg + ∇ ⋅ ( − Pδ + µ∇U )
∂t
∂ρh ∂P (3)
+ ∇ ⋅ ( ρUh ) − ∇ ⋅ ( k∆T ) =
∂t ∂T
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Proceedings of ICAPP ’04
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Paper 4241
needed for the numerical simulation. In fact, viscosity and question to whether the incompressible Navier-Stokes
other physical properties are also temperature dependent in equations are capable of correctly describing complexity
water, and these dependencies must be accounted for in the (e.g., pattern formation) in fluid dynamics. It has been
solution of the Navier-Stokes equations. argued that hyperbolicity is key to preserve (and describe)
shocks, discontinuities and their interactions. While
There are two major issues in using the above model
numerical diffusion expectedly contributes to smearing
to compute and analyze inherently transient processes in
(parabolization), incompressible Navier-Stokes equations
thermal convection. First of all, in order to predict heat
are parabolic in the first place.
transfer in thermal convection, one must be able to
correctly describe the mixing in unstably stratified regions.
Given the above discussion, it is clear while the onset
Since every scheme for numerical discretization of the
of convection and formation of patterns such as those
Navier-Stokes and energy equations involves numerical
observed in the BETA-NC experiments are such an
diffusion, it is important that the numerical diffusion does
invaluable test bed for addressing issues.
not interplay with physical mixing to the level that it
causes the mixing to diminish. Often, physical models are
III.A. Numerical methods and performance
added in an ad hoc manner so to recover the lost mixing
source. However, development and validation of such
models have been a challenge.
A critical analysis of past works as well as a review of Figure 5. Onset and development of thermal
recent advances in turbulence modeling and simulation convection cells in Rayleigh-Benard convection. Note the
revealed that previously intuitive, empirical selection of regularity of initial “bubbles” and their coalescence to
numerical schemes for use in “no model” LES model of form larger loops.
turbulent natural convection in internally-heated liquid
pools has a root in Monotonically Integrated LES (or In the present study, the Fluent code is used for
MILES) method (see Boris et al, 1992). The MILES solving the Navier-Stokes and energy equations (1-3). We
approach has recently received a substantial body of have examined first-order (SIMPLE), second-order
supporting results as well as theoretical basis (Grinstein (SIMPLEC, QUICK) accurate numerical schemes on a
and Fureby, 2002). The chief idea in MILES is that standard Rayleigh-Benard (Figure 5), for which heat
numerical diffusion in an appropriately constructed transfer measurements are available. We found, again, the
numerical scheme plays the role of sub-grid scale mixing, QUICK scheme be applicable. Parameters of spatial and
so that no additional sub-grid scale treatment is required. time discretization were also tested. The new results
confirmed previous experience in Nourgaliev and Dinh
The second issue is of integrated theoretical/ and Nourgaliev et al (1997). In all calculations presented
computational origin; it is built upon the long-standing for analysis of the BETA-NC experiments, non-uniform
grids are used so that thermal/fluid boundary layers be
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Proceedings of ICAPP ’04
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Paper 4241
resolved accurately. The grid refinement effect was also the second-generation bubble appeared (see image for t=
verified. 10.3 s).
The heat transfer problem is solved in a conjugated Figure 7 depicts results of calculations and
formulation that accounts for the localized heat source in temperature measurements. The result is shown for
the film heater and multi-dimension conduction in glass. different points across the heated area (over a length of 20
mm). The simulations shown in Figure 7 were two-
dimensional. Three-dimensional simulation with uniform
heating shows similar time moment when the instability
sets in.
T em p er a tur e (C )
T em p er a tur e (C )
80 80
Point-a Point-b
60 60
4.8s 5.4s 40 40
20 20
0 2 4 6 8 0 2 4 6 8
T em p er a tur e (C )
T em p er a tur e (C )
80 80
6.0s 9.0s Point-c Point-d
60 60
40 40
20 20
0 2 4 6 8 0 2 4 6 8
10.3s
T em p er a t ur e (C )
T em p er a t ur e (C )
80 80
Figure 6. Onset and development of thermal Point-e Point-f
60 60
convection. Two-dimensional simulation of run BETA-NC
I6 (44 kW/m2, 10 mm water layer). Uniform heat flux. 40 40
T em p er a t ur e (C )
Figure 5 depicts results of numerical simulation during 80
Point-g
80
Point-h
the startup phase in Rayleigh-Benard convection. Such 60 60
flow situations may also occur, for example in a transient 40 40
cooldown experiment when a hot pool is subjected 20 20
suddenly to a cooled (upper) boundary. Unfortunately, 0 2 4 6 8 0 2 4 6 8
time (s) time (s)
characterization of flow development in Rayleigh-Benard
convection is not available, so we do not have a direct
Figure 7. Numerical simulations and comparison to
evidence of whether the instability, the growth of bubble,
experimental run (BETA-NC I6 run, 44 kW/m2, 10 mm
their coalescence were predicted correctly, and what are
water layer with an upper wall). Dash-dot line (blue):
possible factors that may govern their behavior.
experiment; solid (black) line: calculation with uniform
heat flux; long-dashed (red) line: calculation with 0.2 mm
non-heating edge; dotted (black) line: calculation with 0.5
III.B. Simulation of the BETA-NC experiments:
mm non-heating edge.
Uncertainty in heat flux uniformity
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Proceedings of ICAPP ’04
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Paper 4241
adjacent to the side walls. The result shown in Figure 7 profile found in this study indicates a source for mismatch
indicates that the thermal boundary layer became unstable between numerical and experimental simulations in
at much early times. The non-heated edge is colder, hence unstably stratified layers. Early instability means the
causing a lateral flow into the heated area. Apparently, the thermal boundary layer in the unstably stratified layer is
disturbances are sufficient and propagated into the heated susceptible to small disturbances due to imperfections, and
area. therefore an enhanced mixing is to be expected.
3.0s 3.1s
3.4s 3.5s
3.8s 3.9s
4.2s 4.4s
4.4s 4.8s
5.6s 6.2s
We have also performed sensitivity analysis for cases
when the surface heat flux is disturbed within a middle
region (as vs to edgy non-uniformity). Figure 8 depicts Figure 9. Simulation of nucleation of “bubbles” upon
results for two cases, with about +7.5% and –5%, in a the thermal convection onset. Central part (40 µm) is with
small area of L ~ 40 µm in length. Transient results heat flux increased 7.5% (shown in the left column) and
showed that the instability is predicted to occur exactly at decreased 5% (shown in the right column). Conditions
the disturbance flux location (point “d”); one “bubble” is simulated are that of BETA-NC I6 run. The flow topology
nucleated at this point for case of “+7.5%” (Figure 9, left is very similar to that of Rayleigh-Taylor instability.
column) and by two “bubbles” right next it for the case
with “–5%” reduced flux (Figure 9, right column). From
the timing point of view, the onset is about 1 second early
(compare Figure 9 with Figure 6), bringing it closer to the III.C. Simulation of the BETA-NC experiments:
experimental observation. However, for the remaining Pattern formation
area, the small disturbance at a center location does not
seem to significantly ease the global thermal convection In this section, we turn our attention to the later stage
onset. Possibly, an increase in length scale L the disturbed of instability development that is the formation of patterns
(power) zone or presence of many disturbed zones may in thermal convection. Figure 2 already exhibits the kind of
lead to the sooner onset of global thermal convection. The thermal patterns observed in the BETA-NC experiments
sensitivity of onset of thermal convection to heat flux (run I6 for 44 kW/m2). Most strikingly, the patterns
observed in experiment I9 are nearly identical to patterns
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Proceedings of ICAPP ’04
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Paper 4241
seen in I1…I8 for heat fluxes from 22 to 44 kW/m2, with experimental measurements shown in Figure 3. It can also
water depth 5 and 10 mm, and with free surface and with be seen that a lower-temperature corridor exists all around
wall upper surface. The two black circles seen in first two the heater surface near the size walls, both in numerical
images in Figure 2 repeated in all runs on I heater. Patterns results and in experimental images. This behavior is related
observed in runs on heater “H” are also similar to each to the asymmetry of the fluid layer near the side wall (due
other. Again, one location near a heater edge cooled first. to non-slip velocity boundary condition applied on the
vertical wall), that caused an earlier onset of convection.
Computationally, rectangular shapes are predicted to have
onset to occur simultaneously around the heater, while in
experiments, the onset appeared in certain locations first,
reflecting the effect of heater conditions on the onset.
4.5s 5s 5.5s 6s
6.5s 7s 7.5s 8s
9
Proceedings of ICAPP ’04
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Proceedings of ICAPP ’04
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Paper 4241
core melt pools). In fact, different heat transfer results convection”, Annual Review of Fluid Mechanics, 32,
were measured in natural convection experiments pp.709-778 (2000).
performed with different walls (materials, conductivity);
e.g. Nikolaenko and Ahler (2003). Additional calculations 6. J. OH and G. Ahlers, “Thermal-noise effect on the
as well as controlled experiments (with pre-defined non- transition to Rayleigh-Benard convection”, Physical
uniformities) are needed to quantify the effect of non- Review Letters, 91 (9): Art. No. 094501 (2003).
uniformity on surface-averaged heat transfer coefficients.
7. R.R. NOURGALIEV, and T.N. Dinh, “An
The 3D numerical simulations performed in this work Investigation of Turbulence Characteristics in an
provided the basis to conclude that the mathematical model Internally Heated Unstably Stratified Fluid Layers”,
based on the Navier-Stokes and energy equations is Nuclear Engng Design, 178:(1), 235-259 (1997).
capable of capturing and predicting the thermal patterns
formed in Rayleigh-Benard convection. The use of a high- 8. T.N. DINH, R.R. Nourgaliev, and B.R. Sehgal, "On
order accurate numerical scheme in this work may have Heat Transfer Characteristics of Real and Simulant
been a significant factor, helping limit the numerical Melt Pool Experiments", Nuclear Engineering and
diffusion. Excessive numerical diffusion is known to delay Design, 169, pp.151-164, 1997.
or even suppress physical instabilities, which are essential
for the physics in unstably stratified flow such as in the 9. T. G. THEOFANOUS, J.P. Tu, A.T. Dinh and T.N.
thermal Rayleigh-Benard convection. Dinh, “The Boiling Crisis Phenomenon – Part 1:
Nucleation and Nucleate Boiling Heat Transfer”, J.
Experimental Thermal and Fluid Science, V.26 (6-7),
ACKNOWLEDGMENTS pp.775-792, (2002).
The work described in this paper was supported by the 10. R.R. NOURGALIEV, T.N. Dinh, and B.R. Sehgal,
U.S. Department of Energy’s International Nuclear Energy "Simulation and Analysis of Transient Cooldown
Research Initiative Program (I-NERI) under contract DE- Natural Convection Experiments", Nuclear
FG06-02RL14337. Basic guidance for this work derived Engineering and Design, 178:(1), pp.13-27 (1997a).
from the BETA program carried out for NASA under
grants NAG3-2119 and NAG3-2761. The authors thank 11. R.R. NOURGALIEV, T.N. Dinh, and B.R. Sehgal,
Mr T. Salmassi for his help with BETA test section design. “Effect of Fluid Prandtl Number on Heat Transfer
Characteristics in Internally Heated Liquid Pools with
Raleigh Numbers up to 1012”, Nuclear Engineering
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11