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Dipartimento di Ingegneria Energetica, Nucleare e del Controllo Ambientale, Universit di Bologna, Bologna, Italy
Laboratory of Heat and Mass Transfer (LTCM), Ecole Polytechnique Fdrale de Lausanne (EPFL), Lausanne CH-1015, Switzerland
a r t i c l e
i n f o
Article history:
Received 29 June 2012
Received in revised form 21 November 2012
Accepted 2 December 2012
Available online 23 January 2013
Keywords:
Flow boiling
Microchannel
Volume Of Fluid
Evaporation
Heat transfer
a b s t r a c t
Flow boiling within microchannels has been explored intensively in the last decade due to their capability to remove high heat uxes from microelectronic devices. However, the contribution of experiments to
the understanding of the local features of the ow is still severely limited by the small scales involved.
Instead, multiphase CFD simulations with appropriate modeling of interfacial effects overcome the current limitations in experimental techniques. Presently, numerical simulations of single elongated bubbles
in ow boiling conditions within circular microchannels were performed. The numerical framework is
the commercial CFD code ANSYS Fluent 12 with a Volume Of Fluid interface capturing method, which
was improved here by implementing, as external functions, a Height Function method to better estimate
the local capillary effects and an evaporation model to compute the local rates of mass and energy
exchange at the interface. A detailed insight on bubble dynamics and local patterns enhancing the wall
heat transfer is achievable utilizing this improved solver. The numerical results show that, under operating conditions typical for ow boiling experiments in microchannels, the bubble accelerates downstream
following an exponential time-law, in good agreement with theoretical models. Thin-lm evaporation is
proved to be the dominant heat transfer mechanism in the liquid lm region between the wall and the
elongated bubble, while transient heat convection is found to strongly enhance the heat transfer performance in the bubble wake in the liquid slug between two bubbles. A transient-heat-conduction-based
boiling heat transfer model for the liquid lm region, which is an extension of a widely quoted mechanistic model, is proposed here. It provides estimations of the local heat transfer coefcient that are in
excellent agreement with simulations and it might be included in next-generation predictive methods.
2012 Elsevier Ltd. All rights reserved.
1. Introduction
Microscale ow boiling is one of the most promising cooling
technologies to dissipate high heat uxes from microprocessors.
The two-phase cooling, applied directly on the chip through microchannels evaporators, is nowadays succeeding in removing more
than 300 W/cm2 from the electronic chip itself. Besides the capability of removing high heat power densities, Agostini et al. [1] argued that the main advantages of two-phase ow boiling heat
transfer compared to other high heat ux cooling methods are:
lower mass ow rate of the coolant due to the high energy absorption by the latent heat of vaporization, lower pressure drop due to
this lower mass ow rate, lower temperature gradients due to saturated ow conditions and the heat transfer coefcient increases
with heat ux. Within microchannels, once nucleation begins at
one location, the vapor bubble grows rapidly and lls the entire
Corresponding author. Address: via Terracini, 34, 40128 Bologna, Italy. Tel.: +39
051 2090541.
E-mail address: mirco.magnini@unibo.it (M. Magnini).
0017-9310/$ - see front matter 2012 Elsevier Ltd. All rights reserved.
http://dx.doi.org/10.1016/j.ijheatmasstransfer.2012.12.010
452
M. Magnini et al. / International Journal of Heat and Mass Transfer 59 (2013) 451471
Nomenclature
Roman Letters
A
area
a
acceleration
B
generic interfacial effect
2
Boa
bubble acceleration Bond number qaD
r
b
generic uid property
Ca
capillary number lrU
h
i1=2
r
Co
connement number
2
g DqD
!
PNDf t
Cr
Courant number
cp
D
Fr
f
G
g
H
h
hlv
I
L
La
Lh
Ls
L2, L1
M
_
m
_g
m
_i
m
_o
m
N
n
p
p
q
qe
R
Re
Rg
r, z
T
t
U
V=
u
u
V
We
velocity vector
dimensionless velocity vector
volume
2
Weber number qUr D
x, y
x
xS
Y
zG
zh
uf nf Af
Greek Letters
a
volume fraction
at
thermal diffusivity
b
eigenvalue
c
accommodation coefcient
D
mesh element size
d
liquid lm thickness
dS
delta-function
dT
thermal boundary layer thickness
j
interface curvature
k
thermal conductivity
l
dynamic viscosity
n
Scriven model growth constant
q
density
r
surface tension coefcient
/
interface kinetic mobility
Subscripts
0
initial conditions
1, 2
primary, secondary phase
b
bubble
c
computational cell centroid value
ex
exact value
f
computational cell face centroid value
if
interfacial
l
liquid
N
bubble nose
sat
saturation
sp
single phase
tp
two-phase
v
vapor
w
wall
z, zz
rst, second order derivatives with respect to z
1
far system conditions
fer coefcient with heat ux, weak effect of the mass ux, but
conicting trends with the vapor quality. This suggested to the
authors that additional phenomena, negligible in the macroscale,
must come into play in microchannels.
Due to the substantial heat ux dependency of the heat transfer
coefcient which is typical of a nucleate boiling controlled regime
in the macroscale, many authors concluded that nucleate boiling is
the governing heat transfer mechanism in the microscale as well.
However, Thome observed in [7] that there is not any experimental
proof to conclude that nucleate boiling is the prevalent regime in
microchannels, hence he advised against the application of macroscale ideas to derive microscale ow boiling methods.
Bertsch et al. [6] compared predictions of 25 published correlations for ow boiling heat transfer against 10 independent data
sets from the published literature. They reported that models
developed specically for the microscale gave no better results
than those for conventional channels, and that Coopers pool
M. Magnini et al. / International Journal of Heat and Mass Transfer 59 (2013) 451471
boiling correlation [9] provided the overall best prediction. However, Coopers correlation was able to predict only the 48% of the
data set with a deviation within 30%. Thus, Bertsch and coauthors remarked the clear need for additional research into the
mechanism of ow boiling in small channels.
Thome et al. [4] developed a three-zone heat transfer model for
the evaporation of elongated bubbles in microchannels. The model
assumes that the evaporation of the thin liquid lm trapped
between the bubble and the channel wall is the dominant heat
transfer mechanism rather than nucleate boiling and estimates a
time-averaged heat transfer coefcient in the liquid lm zone by
one-dimensional steady-state heat conduction across the lm.
The bubble is modeled as a trapezoid and empirical correlations
are used to evaluate its size, which in turn lead to ve adjustable
empirical parameters. Recent papers [1012] have eliminated
one of these, nding that the lm dryout thickness can be set to
the measured wall roughness. The three-zone model is very sensitive to the set of parameters chosen, this has led to very good predictions [1315] as well as poor ones [6,12] when employed to
predict independent ow boiling heat transfer databases.
Recently, Harirchian and Garimella [12] employed the Thome
et al. three-zone model [4] to estimate boiling heat transfer in
the slug ow regime, as part of a comprehensive ow regimebased heat transfer model. They modied the three-zone model
original correlations for initial and minimum lm thickness. With
a new set of empirical parameters, the percentage of data predicted
within 30% increased from 36% obtained with the original
three-zone model to 82% of the new one with the proposed
modications when t to their data set for FC-72. Han et al. [16]
performed liquid lm thickness and wall temperature measurements under ow boiling conditions for water and ethanol and
they found a good agreement between the heat transfer coefcient calculated from measured liquid lm thickness and that
obtained directly from wall temperature measurements. This
conrmed that thin-lm evaporation played a dominant role on
the heat transfer within microchannels.
The three-zone model approach, based on thin lm evaporation
as the prevalent heat transfer mechanism and attempting to reconstruct the actual ow conguration, laid the foundation for a more
reliable physics-based modeling of microscale ow boiling. However, new generation methods cannot prescind from accurate models for the macro-to-micro transition, ow patterns and geometry
of the liquid-vapor interface. Kew and Cornwell [17] for example
recognized the unimportance of gravitational forces as a peculiar
effect of microscale conditions. They observed that heat transfer
and ow characteristics deviate considerably from macroscale
1=2
trends when the Connement number Co gDrqD2
had values
above 0.5. Recently, Ong and Thome [18] measured the lm thickness above and below elongated bubbles in ow boiling conditions
and observed that gravity forces are fully suppressed, such that the
ow is symmetric, when Co > 1. Revellin and Thome [19] and
Harirchian and Garimella [20] proposed diabatic vapor quality versus mass ux ow pattern maps, with transition lines captured
through mechanistic models in order to quantitatively distinguish
the different ow regimes. The accurate estimation of the liquid
lm thickness d surrounding the bubble in the slug ow regime
is fundamental for boiling heat transfer models based on thin lm
evaporation [4,12], as the local heat transfer coefcient in the lm
region is computed as h = k/d. Han and Shikazono performed a
large experimental study of liquid lm thickness measurements
for bubbles in steady motion [21] and under acceleration [22].
By applying a scaling analysis to the forces acting on the bubble
to t their experimental data, they proposed the following
relationship to estimate the lm thickness in laminar ow
conditions:
"
#
d
d
d
min
;
D
D steady
D accel
453
d
0:67Ca2=3
2
2=3
D steady 1 3:13Ca 0:504Ca0:672 Re0:589 0:352We0:629
d
0:968Ca2=3 Bo0:414
a
3
D accel 1 4:838Ca2=3 Bo0:414
a
where the Capillary number Ca lrU, the Reynolds number Re qUD
l ,
the Weber number We = Ca Re and the bubble acceleration Bond
2
number Boa qaD
have to be evaluated at the actual bubble
r
velocity.
2.2. Numerical simulations of ow boiling within microchannels
Recent advances on multiphase computational uid dynamics
allow numerical solution of boiling ows within microchannels
to be performed, thus providing essential information on the local
structure of the ow. Interface capturing techniques for xed computational grids, such as Level Set (LS) [23] or Volume Of Fluid
(VOF) [24] methods, are emerging as one of the best mathematical
and numerical treatments of multiphase ow physics due to their
easiness of implementation, accuracy and robustness of the
algorithms.
Talimi et al. [25] provided a comprehensive review of numerical
studies concerning adiabatic and diabatic slug ow in microchannels without phase change. The simulations of slug ows with heat
transfer reported impressive enhancement of the wall heat transfer
performance along the liquid lm region, as well as remarkable increase of heat transfer coefcients in the wake behind the bubble,
due to local recirculation patterns forced by the bubble motion.
Mukherjee and Kandlikar [26] simulated the ow boiling of a
water vapor bubble within a square microchannel, by use of a LS
method to track the interface. They studied the bubble growth rate
for different liquid superheats and ow velocities and observed
that the vapor bubble grew spherically with a linear timelaw
for the growth rate until it approached the channels walls. Subsequently, the bubble stretched and generated a thin liquid lm,
eventually forming some dry patches, while the growth rate
time-law became exponential.
Suh et al. [27] studied, by means of a LS method, the bubble
dynamics and the associated ow and heat transfer in parallel
microchannels, in order to investigate the conditions leading to
ow reversal. They showed that backows may occur in parallel
microchannels when the bubble formation is not simultaneous in
adjacent channels. This leads to a drop in the heat transfer performance at the wall of the channel where reversed ow occurs and
such an instability is boosted by higher wall superheats and smaller contact angles.
Mukherjee [28], simulating the ow boiling of a bubble in contact with the heated surface of a microchannel, investigated the
role of advancing and receding contact angles between the bubble
interface and channel wall. He reported that the wall heat transfer
is improved by a smaller contact angle, as it promotes the formation of a thin liquid layer trapped between the bubble interface
and the channel wall, thus indicating that thin lm evaporation
is the primary wall heat transfer mechanism in microscale ow
boiling as proposed earlier in [29].
Mukherjee et al. [30] performed a parametric study to assess
the inuence of wall superheat, Reynolds number, surface tension
and contact angles on bubble growth rate and wall heat transfer.
454
M. Magnini et al. / International Journal of Heat and Mass Transfer 59 (2013) 451471
tension force. An evaporation model is introduced within the solver through additional subroutines to estimate the rates of mass
and energy exchange at the interface due to evaporation. The evaporation model allows the interface temperature to deviate from the
saturation condition, according to a physical model developed by
Schrage [40] for interphase mass transfer. Dryout and microlayer
effects are avoided in our simulations by appropriate choice of
the operating conditions for each case. Gravitational effects are
made negligible by choosing operating conditions which lead to
Co > 1 [18]. This allows a two-dimensional axisymmetrical formulation of the ow problem, such that the entire computational effort is aimed to very ne mesh grids and long channels, up to 72
diameters. Abundant use of parallel computations were implemented to decrease the computational time, using up to 128 processors for the simulation run with the longest channel.
4. Numerical framework
4.1. The VOF method
The two-phase ow problem is formulated through a singleuid approach, such that a unique velocity, pressure and temperature eld is shared among the phases. A single set of ow equations
is written and solved throughout the domain and the phases are
treated as a single uid, whose properties change abruptly across
the interface. The ow problem, along with boundary conditions,
is similar to that of a single phase ow; however additional
arrangements are necessary: denition of a marker function to
identify each uid, a method to update the marker function as
the interface evolves, mathematical modeling of interfacial effects
and discretization on the computational grid.
The Volume Of Fluid method denes a marker function I(x,t) as
a multidimensional Heavyside step function with the value 1 in the
primary phase and 0 in the secondary phase. The discrete version
of the indicator function is the volume fraction a, obtained by integration of I(x,t) over the computational cell of volume V:
1
V
Ix; t dV
The so-dened volume fraction represents the ratio of the cell volume occupied by the primary phase. It is 1 if the cell is lled with
the primary phase, 0 if lled with the secondary phase and
0 < a < 1 for an interfacial cell with both phases inside. The generic
uid property b for every domain cell can be expressed in terms of a
as follows:
b b2 b1 b2 a
where b1 and b2 are primary and secondary phases specic properties. Since the volume fraction is transported as a passive scalar by
the ow eld, its values can be updated by solving a transport equation. The interfacial effects are modeled as delta functions concentrated at the phases interface. By referring to dS = d(x xS) as a
multidimensional delta function which is non-zero only on interface points xS, the generic interfacial effect B(x) is introduced within
the ow equation as the source term B(x)dS. According to the VOF
approach, the delta function is represented in the computational
grid as dS = jraj. Since ra 0 on the few layers of cells laying
across the interface, the interface is meant as a transition region
with nite thickness, where interfacial effects are concentrated
and the uid properties vary according to Eq. (5).
4.2. Governing equations
In this work both phases are always assumed incompressible. It
is worth to note that the density of the vapor phase may decrease
M. Magnini et al. / International Journal of Heat and Mass Transfer 59 (2013) 451471
ru
qv
ql
1
1
_ S
_ raj
md
mj
qv
ql
where the r.h.s. of Eq. (6) accounts for the uid expansion due to
_ The forphase change by introducing the interphase mass ux m.
_ is the task of the evaporation modmulation and computation of m
el, which is presented in Section 4.3. Note that, within the bulk
phases, the Eq. (6) reduces to the well-known divergence-free condition for the velocity eld r u = 0.
To evolve the interface location, the following volume fraction
conservation equation for ow with phase change is solved:
@a
1
1
_
_ raj
md
mj
r au
@t
qv S qv
@qu
r qu u rp r l ru ruT qg F r
@t
F r rjndS rjnjraj
@qcp T
_ lv cp;v cp;l Tjraj
r qcp uT r krT mh
@t
10
which at the r.h.s. shows the energy source terms given by the
_ lv , with hlv being the latent heat of vaporization,
evaporation mh
_ p;v T and that of the liquid rethe enthalpy of the vapor created mc
_ p;l T, with cp being the constant pressure specic heat.
moved mc
The energy equation (10) does not include the viscous heating
term. Following the dimensional analysis proposed by Morini
[42], the viscous heating contribution was estimated here on the
uid bulk temperature for a single phase ow under operating conditions representative of the cases simulated. It was found to be of
the order of 104 compared with the rise in temperature generated
by the wall heat ux, and therefore the viscous heating effect is
negligible in our simulations. The variation of the uid temperature in the simulations performed is sufciently small such that
the uid specic properties are considered constant throughout
the ow domain.
455
_
m
1=2
2c
M
pv
pl
p
p
2 c 2pRg
Tv
Tl
11
where M is the molecular weight and Rg = 8.314 J/mol K is the universal gas constant, pv and Tv are the vapor pressure and temperature at the interface, pl and Tl are the liquid pressure and
temperature at the interface.
The accommodation coefcient is difcult to be measured
experimentally and it is known only for a few liquids, with a large
degree of uncertainty. Marek and Straub [44] analyzed the published data for water and reported values in the range from 103
to 1. Rose [45] performed a review of experimental results on dropwise condensation and concluded that the most reliable values for
c were close to unity. Wang et al. [46] showed that non polarliquids have an experimentally determined accommodation
coefcient of unity. As it will be discussed in the Section 5.3, we
found the best agreement with analytical solutions by setting c = 1.
Tanasawa [47] assumed that for small interface temperature
jumps, such that (Tv Tif) Tv, the interphase mass ux depends
linearly on the temperature jump between the interface and the
vapor phase:
_
m
1=2
qv hlv T if T v
2c
M
2 c 2pRg
T 3=2
v
12
_ /T T sat p1
m
13
1=2
2c
M
qv hlv
2 c 2pRg
T 3=2
sat p1
14
456
M. Magnini et al. / International Journal of Heat and Mass Transfer 59 (2013) 451471
is subtracted from the energy stored within the cell, such that the
temperature drops locally to a value close to the saturation condition. Therefore, the interface temperature is always equal or little
above the saturation value.
The mass and energy source terms at the r.h.s. of Eqs. (7) and
(10) are concentrated at the 23 cells laying across the interface.
Such source terms localized in a narrow region may give rise to
numerical instabilities when the rate of mass and energy production is high. Hence, a mathematical procedure was implemented
to smear the source terms over a few cells across the interface,
as proposed by Hardt and Wondra [48]. The solution of a diffusion
equation for the original evaporation rate provides a smooth evaporation rate eld. Then, the use of volume fractions and normalization factors allows the newly created vapor to concentrate on the
vapor side of the interface and liquid to disappear on the liquid
side, always ensuring global mass conservation. The reader is referred to [48] for a detailed description and validation of the procedure. In order to test the entire evaporation model, a vapor bubble
growing in superheated liquid was simulated and the results are
reported in Section 5.3.
4.4. Height Function algorithm
Generally speaking, once an approximation of the interface unit
normal vector n is built, the local curvature can be derived as
j = r n [41]. ANSYS Fluent (version 12 and earlier) computes
the interface unit norm vector as n = ra/jraj according to early
Youngs PLIC (Piecewise Linear Interface Calculation) formulation
[49], and it estimates the curvature by differencing volume fractions. However, such an approach is known to have poor accuracy
as the volume fraction changes abruptly across the interface and
standard derivation schemes do not converge when applied to
strongly discontinuous functions. The consequence is the creation
and growth of unphysical velocities, known as spurious velocities
or parasitic currents [50], which may lead to unreal deformation
of the interface, up to its breaking-off. Furthermore, these numerical artifacts articially increase heat convection at interfaces,
speeding up evaporation or condensation phenomena through a
purely numerical process.
To overcome this limitation, a Height Function algorithm was
implemented to replace the ANSYS Fluent default method to estimate curvatures. Let y = f(x) be the mathematical function identifying the interface line in a Cartesian (x,y) reference frame, as shown
in Fig. 1. The height function H(x;D) represents the height of the
interface line f(x), averaged within a local stencil of width D and
centered on x:
Hx; D
1
D
xD=2
f tdt
xD=2
15
1
1 Hz 2 1=2
j r n
Hz ; 1
16
Hzz
2 3=2
1 Hz
Hzz
1
jHzz j f z1 Hz 2 1=2
17
where Hz and Hzz denote the rst and second order derivatives with
respect to z and f(z) is the local elevation of the interface over the
revolution axis.
The HF algorithm implemented here is a combination of the
Malik et al. [51] and Hernandez et al. [52] versions, with the addition of a self-developed routine to estimate the local interface elevation f(z). The algorithm is written for two-dimensional and
axisymmetrical geometries, with constant grid spacings. In Section 5, the performance of our implementation of the HF algorithm
is assessed by several validation benchmarks.
4.5. The ow solver
ANSYS Fluent discretizes and solves the ow equations by
means of a nite-volume scheme. The volume fraction Eq. (7) is
discretized in time with a rst order explicit scheme and the convective term is computed through a geometrical PLIC [49] reconstruction of the uxes across the faces of each interfacial cell.
The numerical stability of the explicit PLIC scheme poses a limitation on the maximum time step allowed to solve the volume fraction equation, since the interface must travel less than one grid cell
at each time interval. The time step for the volume fraction equation is calculated by the solver according to the maximum Courant
number (Cr) allowed for interface and near-interface cells. The
Courant number is a dimensionless number that compares the
simulation time step Dt and the time it would take for the uid
to empty out of the cell:
Cr
Dt
PN f
V= f uf nf Af
18
where V is the volume of the cell and the sum loops on the Nf
boundary faces of the cell. The Fluent default value of Cr = 0.25
was used here.
The momentum and energy equations are discretized in time
with a rst order implicit formulation, which allows a coarser time
step than the volume fraction one. A variable time step technique
was adopted with a maximum Courant number of 0.5 and therefore the volume fraction eld is updated more frequently than
the velocity and temperature elds. The convective terms within
momentum and energy equations are discretized with a third order MUSCL (Monotonic Upstream-centered Scheme for Conservation Laws) [53] scheme, while the diffusive terms are discretized
with a central nite-difference scheme. The cell-centered gradients
of each scalar eld are computed from the scalar values at the cell
face centroids, by means of the Green-Gauss theorem. The Fluent
GreenGauss node-based formulation [54] was proved to be the
best option to enforce the balance among pressure and surface tension within the momentum equation when the HF algorithm is
employed, leading to spurious velocities of two orders of magnitude smaller than other options available in the solver. Furthermore, Gupta et al. [55] reported smaller unphysical pressure
oscillations at the interface of a bubble when the node-based formulation was employed rather than a cell-based one.
The mass conservation equation (6) is turned into a pressure
correction equation which is coupled to the momentum equation
(8). The pressurevelocity coupling is handled by a PISO (Pressure
Implicit Splitting of Operators) [56] algorithm, which was proved
M. Magnini et al. / International Journal of Heat and Mass Transfer 59 (2013) 451471
L1 j
jex
for i 1; . . . ; Ni
19
where Ni is the number of interfacial cells, ji is the ith cell computed curvature and jex = 1/R is the exact curvature of the droplet.
Fig. 2 reports the values of L1(j) under mesh renement for HF and
457
Fig. 2. L1(j) error norm convergence rate. White circles are HF errors and black
diamonds are those of Youngs. The solid line is the second order convergence curve.
L1 ju j
1=2
2qR
maxjui j for i 1; . . . ; N
20
v
uN
int
uX
1
Dpi Dpex 2
t
L2 Dp
Dpex i1
Nint
21
458
M. Magnini et al. / International Journal of Heat and Mass Transfer 59 (2013) 451471
where Nint is the number of interior droplet cells. Fig. 3(a) reports
the velocity error norms after one simulation time step. The
Youngs-based algorithm generates spurious vortices whose magnitudes increase with the mesh renement, as the curvature estimation gets worse by rening the numerical grid. The Height Function
method exhibits velocities which scale with a convergence rate between the rst and second order with respect to the mesh element
size, in good agreement with Francois at al. [38] observations. When
the nest R/D = 40 computational grid is employed, the parasitic
currents induced by the HF algorithm are three orders of magnitude
lower than Youngs generated ones. Such an improvement of the
standard commercial code is favorable to simulate elongated bubbles within microchannels, because the domain mesh is typically ner than R/D = 40. When the Fluent default estimation of curvatures
is employed, the magnitude of the spurious ows may easily approach that of the physical phenomenon being simulated, thus rendering the results unusable. Fig. 3(b) plots the errors in the
computed pressure eld after one simulation time step. The Height
Function computation exhibits a convergence rate between the rst
and second order as the mesh is rened. The Youngs algorithm gives
a converging pressure eld only when R/D 6 10; however at higher
mesh resolutions the average pressure within the droplet deviates
only by 1% from the exact value, which is a reasonable error.
5.3. Vapor bubble growing in superheated liquid
The heat-transfer-controlled growth of a spherical vapor bubble
in an innitely extended superheated liquid was simulated.
According to the analysis of Plesset and Zwick [58] on the bubble
growth process, the heat-transfer-controlled growth reaches an
asymptotic stage in which the growth of the bubble is limited by
heat transport to the interface. The pressure within the bubble is
equal to the liquid pressure increased by the pressure jump at
the interface and the temperature of the vapor is equal to the saturation temperature for that pressure. Scriven [59] has derived an
analytical solution for this stage neglecting viscous and surface
tension effects and considering the interface to be at the saturation
temperature. He obtained the following time-law for the bubble
radius:
p
Rt 2n at t
22
Fig. 3. (a) L1(juj) and (b) L2(Dp) error norms after one simulation time step. White circles are HF errors and black diamonds are Youngs ones. The dashed line is the rst
order convergence curve and the solid line is the second order curve.
M. Magnini et al. / International Journal of Heat and Mass Transfer 59 (2013) 451471
PN
zc ac V c
zG Pc1
N
c1 ac V c
459
23
Ub
Fig. 4. Vapor bubble radius over time for analytical (lines) and numerical (symbols)
solutions.
Ul
1 4 Dd 1 Dd
24
r
64 1
L
Dp 1:08
qU 2 s
3Ca2=3 Re1=3
Re 2
D
D
25
460
M. Magnini et al. / International Journal of Heat and Mass Transfer 59 (2013) 451471
Table 1
Comparison of numerical results and correlations. The errors between parenthesis are computed as
Ca
d/D
Ub [m/s]
100.
0.025
Re
Dp [Pa]
jcorrnumj
corr
Eq. (25)
num (err)
Eq. (2)
num (err)
Eq. (24)
num (err)
15.625
62.5
312.5
625
60
52 (13.3)
0.0494
0.05 (1.2)
0.308
0.308 (0)
65
54 (16.9)
0.0495
0.047 (5.1)
0.308
0.305 (1)
69
71 (2.9)
0.0526
0.05 (4.9)
0.312
0.305 (2.2)
73
80 (9.6)
0.0578
0.06 (3.8)
0.32
0.315 (1.6)
Ca
0.0125
Re
15.625
62.5
312.5
625
62
57 (8.1)
0.0331
0.0279 (15.7)
0.287
0.279 (2.8)
67
58 (13.4)
0.0333
0.028 (15.9)
0.287
0.278 (3.1)
74
61 (17.6)
0.0352
0.035 (0.6)
0.289
0.285 (1.4)
80
82 (2.5)
0.0379
0.038 (0.3)
0.293
0.291 (0.7)
Dp [Pa]
d/D
Ub [m/s]
Eq. (25)
num (err)
Eq. (2)
num (err)
Eq. (24)
num (err)
Fluid
G [kg/m2 s]
Tsat [C]
q [kW/m2]
La
Lh
1
2
3
4
5
R113
R113
R245fa
R134a
R245fa
600
600
600
500
550
50
50
50
31
31
9
20
20
20
5
8D
8D
8D
8D
16D
12D
22D
22D
22D
56D
M. Magnini et al. / International Journal of Heat and Mass Transfer 59 (2013) 451471
461
UP
Fig. 6. Initial temperature eld within the channel, wall temperature (dashed line) and heat transfer coefcient (solid line) for simulation Case 1. The bubble interface is
represented by the black line prole at the upstream of the channel. The channel image is stretched vertically to enlarge the thermal boundary layer at the heated wall.
q
T w T sat
26
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M. Magnini et al. / International Journal of Heat and Mass Transfer 59 (2013) 451471
Fig. 7. (a) Velocity of the bubble nose, (b) bubble growth rate.
Fig. 8. Errors in mass conservation throughout the simulation for Case 1 run with
the D/D = 300 computational grid. The absolute error is reported in kg/s units.
q qv
_im
_ g t l
_ o t m
m
qv
27
_ i and m
_ o are the mass ow rates across the inlet and outlet
where m
_ g is the global rate of vapor creation, obtained by
sections and m
_ raj throughout the domain. Fig. 8 depicts the erintegration of mj
rors on the mass balance expressed in Eq. (27). The relative error,
intended as absolute error normalized by the l.h.s. of Eq. (27), always remains under 106 as time elapses and vapor is being created. This means that mass conservation is ensured during bubble
growth. In addition, according to tests, at each time step the unbalance between vapor created and liquid disappeared is of the order
of machine accuracy, and hence all the liquid removed due to evaporation is actually converted into vapor.
7. Flow boiling of an elongated bubble within a horizontal
microchannel: results and discussion
7.1. Bubble dynamics and comparison with a theoretical model
The bubble dynamics during ow boiling for Case 1 is analyzed.
Fig. 9 reports some snapshots of the bubble evolution while owing within the microchannel. The bubble nose enters the heated region of the channel a little after 4.5 ms, while the plot of the bubble
growth rate shown in Fig. 7(b) (blue color) suggests evaporation to
start at 6 ms, when the bubble interface gets in contact with the
zN t z0
G qv hlv D
4q
exp
t t 0 1
ql 4q
qv hlv D
28
where z0 and t0 are the axial location and time instant at which the
bubble nucleates. In the present simulations, the bubble is generated before entering within the heated region, hence z0 locates
the entrance in the heated region and t0 the time instant at which
the nose of the bubble crosses z0. In the theoretical model the velocity of the bubble when t = t0 equals the velocity of the liquid inow,
while in the simulations the bubble velocity before evaporation begins exceeds that of the liquid as expressed by Eq. (24). Thus, in order to have the same initial velocity of the bubble for the simulation
and the model, the second term on the r.h.s. of Eq. (28) is multiplied
by the reciprocal of the denominator of the r.h.s. of Eq. (24).
Fig. 10(a) shows the comparison of simulation and theoretical
bubble nose positions for Case 1. The exponential time-law is well
captured by the simulation. The curves overlap at the initial stage
of the bubble evaporation, but afterwords the model underestimates the bubble velocity and, as time elapses, this deviation
slowly grows. The origin of the gap is within the mentioned
assumptions of the theoretical model. In the model the bubble
M. Magnini et al. / International Journal of Heat and Mass Transfer 59 (2013) 451471
463
Fig. 9. Bubble evolution during evaporation for Case 1. The black dashed line indicates the entrance in the heated region.
Fig. 10. (a) Time evolution of bubble nose position for Case 1 obtained with simulation compared with Consolini and Thome theoretical model [66]. (b) Equivalent heat ux
absorbed by evaporation.
grows only due to the wall heat ux, while in the simulation the
bubble grows also absorbing the sensible heat of the superheated
liquid, which is able to store energy before the bubble transits.
Thus, the heat used to evaporate the liquid may be smaller than
the wall heat ux or exceed it. In order to obtain an estimation
of the time-varying equivalent heat ux qe absorbed by the evaporation, the heat absorbed to generate vapor is divided by the
heated surface actually traveled by the bubble at the time instant t:
qe
dV b =dtqv hlv
pDzN t z0
29
Fig. 10(b) shows that qe > q from t = 8 ms on, where 8 ms is the time
instant at which the bubble has entered completely within the
heated region. As time elapses and the bubble nose ows downstream to the heated channel, it comes across regions more and
more superheated, and therefore qe rises monotonically as a consequence of the increasing evaporation rate. Within the hypothesis of
wall heat ux used only to evaporate liquid, qe represents the wall
heat ux actually felt by the bubble, and therefore when qe > q Eq.
(28) leads to the underestimation observed in Fig. 10(a).
Numerical and theoretical results are compared in Fig. 11 for
simulation cases 2, 3, 4 and 5, and despite the systematical underprediction of the model at the later stage of the growth as noted
above, the agreement is good. Note that among the simulations
run under the same heat ux (cases 2, 3, 4), the operating uid
R113 gives the fastest growing bubble, while the vapor bubble of
R134a is the last to reach the end of the channel. Due to similar
464
M. Magnini et al. / International Journal of Heat and Mass Transfer 59 (2013) 451471
Fig. 11. Time evolution of bubble nose position obtained with simulations compared with Consolini and Thome theoretical model [66].
heat uxes and mass ow rates, the bubble growth rate depends
mainly on liquid-to-vapor density ratio, kinetic mobility and liquid
specic heat of the operating uids. The specic heat represents
the capacity of the uid to store thermal energy with low temperature gradients, hence it is responsible for the rate of liquid superheating at the wall which determines the local interphase mass
ux, see Eq. (13). Furthermore, from Eq. (13) it follows that the
mass of vapor created is proportional to the kinetic mobility. The
density ratio has a strong effect on bubble growth in volume, as
the lighter is the gas phase than the liquid which it replaces, the
more the liquid evaporated expands when it is converted into vapor. The R113 has the lowest kinetic mobility, 24 kg/m2s K against
58 kg/m2s K of R245fa and 111 kg/m2s K of R134a at the given
operating conditions. Thus its rate of vapor creation would be the
lowest one if all the uids share the same temperature eld. However, R113 has also the lowest liquid specic heat (943 J/kg K
against about 1400 J/kg K of the others), and thus it leads to the
highest liquid superheating and this partially balances the lower
kinetic mobility. What makes the R113 the fastest growing vapor
bubble is its higher liquid-to-vapor density ratio, which is three
times that of R245fa and six times R134a. Therefore, even though
at the end of the simulations R134a has the highest rate of mass
of vapor created, the evaporation of R113 generates the largest
bubble and it is the rst to reach the end of the channel.
7.2. Analysis of ow and temperature eld around the bubble
The temperature and ow elds obtained by the simulation of
Case 1 (uid R113, see Table 2) are analyzed, in order to investigate
the local patterns of the ow and the dominating heat transfer
mechanisms. The ow is captured at the time instant t = 12.5 ms,
before the bubble exits the ow domain. At this time instant the
velocity of the nose of the bubble is 1.07 m/s, the center of gravity
moves at 0.76 m/s and the bubble rear at 0.47 m/s. The axial location of the bubble nose at the center of the channel is z/D = 18.91
and the location of the rear is z/D = 12.43.
Fig. 12 depicts the contours and isolines of the velocity eld
within the heated region of the channel, together with the proles
of the axial and radial velocities averaged within the crosssectional area occupied by the liquid. Average values are evaluated
as:
umean z
2
2
R R dz
ur; zrdr
30
Rdz
where d(z) = R in the absence of the bubble. Isotherms and temperature contours are reported in Fig. 13 together with the wall heat
transfer coefcient estimated as expressed in Eq. (26). The single
phase heat transfer coefcient refers to the preliminary steady
state simulation run with only liquid. A black dashed line represents the thickness of the thermal boundary layer dT for the single
phase case computed as dT(z) = R r(T = Tsat + 0.01(Tw(z) Tsat)),
where the value 0.01 was arbitrarily chosen to identify the thermal
boundary layer as that region whose temperature exceeds the
saturation value by at least 1% of the local wall superheating
(Tw(z) Tsat). Fig. 14 reports the two-phase boiling heat transfer
coefcient htp along the heated wall, relative to the local single
phase value hsp obtained as result of the preliminary single phase
simulation.
Four separate regions can be identied by observation of the
ow and temperature elds across the bubble and each region is
ruled by specic wall heat transfer mechanisms:
M. Magnini et al. / International Journal of Heat and Mass Transfer 59 (2013) 451471
465
Fig. 12. Average liquid axial and radial velocity (above) and contours of the velocity eld (below). The thick black solid line identies the bubble interface.
Fig. 13. Heat transfer coefcient (above) and contours of temperature eld (below). The thick black solid line identies the bubble interface. The black dashed line represents
the width of the thermal boundary layer for the single phase case.
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M. Magnini et al. / International Journal of Heat and Mass Transfer 59 (2013) 451471
Fig. 14. Enhancement of the heat transfer coefcient given by the boiling twophase ow (subscript tp) relative to the single phase case (sp). The black dashed
lines identify the bubble rear and nose positions.
Fig. 15. Proles of liquid axial velocity in (a) the bubble wake and (b) liquid lm.
Fig. 16. Proles of liquid temperature in the bubble wake. Solid line: two-phase ow, dashed line: single phase ow.
M. Magnini et al. / International Journal of Heat and Mass Transfer 59 (2013) 451471
467
Fig. 17. Proles of liquid temperature in the lm region. Solid line: two-phase ow, dashed line: single phase ow. Thick solid line: location of the bubble interface.
Fig. 18. Temperature (left) and axial velocity (right) proles at z/D = 19. Solid line: two-phase ow; dashed line (left): single phase ow; dashed line (right): laminar fully
developed ow with the same liquid ow rate.
q
Ty; t T sat y
k
31
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M. Magnini et al. / International Journal of Heat and Mass Transfer 59 (2013) 451471
Fig. 19. Proles of the liquid temperature within the lm region for the simulation Case 2, evaluated at zh/D = 5. Solid line with asterisks: simulation data; dash-dotted line
with diamonds: steady heat conduction model Eq. (31); dashed line with circles: transient heat conduction model Eq. (37); horizontal thick line: location of the bubble
interface.
Eq. (31) within the relationship (26), the following relationship for
the local heat transfer coefcient yields:
ht
k
dt
32
The consequence of the model errors in the wall temperature prediction is the overestimation of the heat transfer coefcient.
Fig. 20(a)(d) prove that the model leads to coefcients substantially higher than the present simulations, with time-averaged values more than 60% above for all the runs.
The three-zone model has been widely validated through comparison of the predicted time-averaged boiling heat transfer coefcient with several experimental databases. However, the original
three-zone model supposes a lm thickness of the order of 1/100
the channel size, while in the present simulations d/D 1/20.
Within such a thick liquid lm, the thermal inertia of the liquid
might be not negligible, because the time scale of the thermal phenomenon approaches that of the residence time of the liquid lm.
In this situation, a heat transfer model based on transient heat conduction might capture the local physics of the lm better than a
steady-state model. In order to test this hypothesis for the operating conditions simulated in cases 2 to 5, an extended version of the
heat transfer model which leads to the Eq. (31) is obtained by adding the transient term to the one-dimensional Fourier equation:
@T
@2T
at 2
@t
@y
33
Ty 0; t T sat
@T
k y dt; t q
@y
34
35
Ty; t 0 Fy
36
M. Magnini et al. / International Journal of Heat and Mass Transfer 59 (2013) 451471
469
Fig. 20. Time-evolution of the heat transfer coefcient for simulation runs 2 to 5. Solid line: simulation data; dash-dotted line: steady heat conduction model with actual
time-varying liquid lm thickness; dashed line: transient heat conduction model with constant lm thickness.
By considering a constant lm thickness d the thermal problem allows the following analytical solution [68]:
m
q
2X
2
Ty; t T sat y
eat bi t Y i y
k
d i1
Y i y0 Fy0 dy
37
value set in the model, the theoretical and numerical proles get
closer and then overlap partially after 2.81 ms. Afterwards, the
wavy prole of the bubble rear transits and the temperature prole
in the simulation follows the dynamics of the interface. The wall
temperature is little affected by local vortices and lm thickness
oscillations, and hence the wall temperature estimation remains
reliable in this region as well. The bubble rear crosses the axial location analyzed after about 4 ms. The transient heat conduction model suggests that quasi-steady-state conditions for the temperature
within the liquid lm would be reached only after 20 ms. This conrms that, for the operating conditions simulated here, the transient heat conduction is the dominant heat transfer mechanism.
However, Eq. (37) estimates that 0.3 ms would be sufcient for
the temperature eld to attain a steady condition in a lm ten times
thinner, and hence a steady heat conduction modeling might be satisfactory in that case.
Fig. 20(a)(d) show that the prediction of the heat transfer coefcient given by the extended model agrees very well with the results of the numerical simulations for Cases 25. Case 1 was not
studied as the channel is too short. At initial time-steps the proles
may differ due to the initialization of the temperature within the
model, but as the time elapses the enhancement of the heat transfer performance is well captured. The transient heat conduction
model gives time-averaged predictions of the heat transfer coefcient within the 5% of numerical results for Cases 2, 3, 4 and 9%
higher for Case 5. The reason of the systematic model overprediction is twofold. In the simulations, the value of the lm thickness
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M. Magnini et al. / International Journal of Heat and Mass Transfer 59 (2013) 451471
set in the model is reached only at the latest stage of the bubble
passage, while before it is actually thicker such that the heat removal is less efcient. In addition, the transit of the bubble nose
(which identies t = 0) may not coincide with the beginning of
the heat-conduction-controlled stage for the ow and the energy
transport by heat convection might be dominant until the lm
thickness drops below a threshold value.
8. Conclusions
We have modied the commercial CFD solver ANSYS Fluent by
implementing a Height Function interface reconstruction algorithm and an evaporation model as external self-developed functions. This improved solver enabled a very detailed insight in the
bubble dynamics and local phenomena affecting the wall heat
transfer during ow boiling in a microchannel. The working conditions investigated in this work include three different refrigerant
uids, namely R113, R134a and R245fa, circular channels of
0.5 mm diameter, mass uxes ranging from 500 kg/m2s to
600 kg/m2s, heat uxes from 5 kW/m2 to 20 kW/m2 and saturation
temperatures of 31 C and 50 C. As the bubble enters the heated
region of the channel and comes in contact with the superheated
thermal boundary layer developing at the wall, the bubble nose
accelerates downstream following an exponential time-law, in
good agreement with a theoretical model available in the literature. Under similar operating conditions, the high liquid-to-vapor
density ratio of R113 leads to the most rapidly expanding bubble.
The bubble transit at a given axial location pushes liquid against
the microchannel wall and locally cools down the thermal boundary layer as an effect of the evaporation occurring along the liquid
lm region. The heat transfer coefcient increases monotonically
as the lm thickness falls, up to 25% of the liquid-only case near
the bubble rear, thus conrming that lm evaporation is the primary wall heat transfer mechanism. However, the enhancement
of the heat transfer performance remains considerable as well in
the wake region next to the bubble, as a consequence of the superposition of liquid-wall transient heat convection and attened liquid velocity prole. The latter prevents the wall thermal layer
from restoring to the steady situation that was holding before
the bubble transited. A heat transfer method for the liquid lm region based on steady one-dimensional heat conduction overpredicts the local values of the heat transfer coefcient measured in
the present simulations, as the thermal inertia of the liquid is not
negligible (D/d 20 in the present simulations). A new method
including thermal transient conduction within the mathematical
model is able to predict local heat transfer in remarkable agreement with numerical results for all the simulated runs. This model
might be used to extend the existing microchannel boiling heat
transfer methods to cover a wider range of diameter-to-lm-thickness ratios.
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