Single Phase Liquid Flows in Microchannel

ME 6004
MICRO AND NANOSCALE ENERGY

TRANSPORT
Single Phase Liquid Flows in Minichannels
and Microchannels
Prof. Arvind Pattamatta
Heat Transfer & Thermal Power (HTTP) Laboratory
Department of Mechanical Engineering
IIT Madras
10/25/2016
Dr. Arvind Pattamatta
Main Areas Currently Investigated

Experimental validation of the laminar and turbulent ow
transport equations. (Momentum and Energy equations are
expected to be applicable for microchannels.)
Verication of the laminar-to-turbulent ow transition at
microscale. (Experimental evidence in this regard needs to be
critically evaluated.)
The effect of large relative roughness values on the ow.
(Their effect on friction factor, heat transfer needs to
investigated.
Verication of empirical constants derived from macroscale
experiments needs to be validated with micro and
minichannels.
10/25/2016
Pressure Drop in Single-Phase Liquid Flow

Assume a flow through 1-D, incompressible, circular smooth
pipe.
Assuming continuum assumptions to be valid for Newtonian
liquid flows in minichannels and microchannels.
Considering equilibrium of a fluid elements of length dx in
a pipe of diameter D.
Balancing the frictional force and shear stress we get:
Therefore, shear stress and pressure gradient are related as:
10/25/2016
Pressure Drop in Single-Phase Liquid Flow

Continued .
For Newtonian fluids:
Fanning factor f is given by:
where, um is the mean velocity.
For noncircular flow channels, D is replaced by hydraulic
diameter.
where, Ac is the flow channel cross-section and Pw is the
wetted perimeter.
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Fully Developed Laminar Flow

For a fully developed flow through circular-pipe, the friction
factor f is given by:
where, Po is Poiseuille number which depends on flow
geometry.
For, circular pipe Po = f * Re = 16
Shah and London(1978) provided the following equation for
a rectangular channel for side a and b.
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Fully Developed Laminar Flow continued .

Fanning Factor and
Nusselt number for
Fully developed
Laminar flow in
Ducts Kakac et al.
(1987)
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Developing Laminar Flow

The length of the hydrodynamic developing region Lh:
In small diameter channels pressure gradients are quite high,
so the flow lengths are kept low.
Thus, the major portion of the flow is in developing region.
The pressure drop in a channel is given by:
where, fapp accounts for pressure drop and the developing

effects. It represents an average value of the friction factor
over the flow length between entrance and the location under
consideration.
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Developing Laminar Flow continued .

Difference between the incremental pressure and the fully
developed friction factor over the length x is given by
incremental pressure:
For x > Lh, incremental pressure attains the constant value

known as Hagen Bach's factor K().
So, the pressure drop in term of incremental pressure is:
Shah and London(1972) given the equation for the pressure

drop as:
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x+ is non-dimensional length given by:
Frictional pressure drop for circular duct is given by:
Steinke and Kandlikar (2005) obtained the curve fit for the
Hagenbachs factor for rectangular channels as:
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Apparent friction factor for rectangular ducts in the developing region for
different aspect ratios. c = a/b
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10
Fully developed and developing turbulent flow

Blasius developed the correlation:
Phillips (1987) developed the expression for developing and
developed regions.
He presented Fanning friction factor for a circular tube as:
where,
For rectangular geometries Re is replaced by laminarequivalent Reynolds number given by:
where, Dle is the laminar-equivalent diameter.

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11
Total Pressure Drop in Microchannel Heat

Exchanger
Schematic representation of the experiments employed by

researcher fro pressure drop measurements in microchannels.
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12
Total Pressure Drop in Microchannel Heat Exchanger

continued .
The pressure drop measurement represents the combined
effects of the losses in the bend, entrance and exit losses,
developing region effects, and core frictional losses.
So, the pressure drop is given by:
where, Ac and Ap are the total channel area and the total
plenum cross-sectional area, K90 is the loss coefficient at the
900 bends, Kc and Ke represents the contraction and
expansion loss coefficient due to area changes, and fapp
includes the combined effects of frictional losses and
additional losses in developing flow.
10/25/2016
13
Total Pressure Drop in Microchannel Heat Exchanger

continued .
In terms of the fully developed friction factor f and pressure
drop defect K(x):
For L>Lh, K(x) is replaced by the Hagenbachs factor K()
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14
Laminar to Turbulent transition

Laminar to turbulent transition in smooth microchannel is
not influenced by the channel dimensions and occurs around
Re = 2300.
Comparison between theory

and experiments fro circular
tubes in the fully developed
region.
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15
Roughness Effects
Parameters based on various roughness characterization
schemes are investigated by Kandlikar (2005):
Average maximum prole peak height (Rpm): The distance

between the average of the individual highest points of the prole
(Rp,i) and the mean line within the evaluation length. The mean
line represents the conventional average roughness value (Ra).
10/25/2016
16
Roughness Effects continued .

Mean spacing of prole irregularities (RSm): consists of the
mean value of the spacing between prole irregularities within the

evaluation length. The irregularities of interest are the peaks, so
this is equivalent to the Pitch.
Floor distance to mean line (Fp): Consists of the distance
between the main prole mean line (determined by Ra) and the
oor prole mean line. The oor prole is the portion of the main
prole that lies below the main prole mean line.
Equivalent roughness:
10/25/2016
17
Roughness Effects on friction factor

Constricted flow model:
Kandlikar et al. (2005)
considered the effect of crosssectional area reduction due to
protruding roughness elements
and recommended using the
constricted ow area in
calculating the friction factor.
So a modified Moody diagram

was formulated based on the
constricted diameter.
Modified Moodys Chart
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18
Constricted flow model

The flow and geometrical parameter based on the
constricted flow diameter is given by:

,
and
For fully developed laminar flow and 0 < /Dcf < 0.15
we have:
where, Po is Poiseuille number
10/25/2016
19
Constricted flow model continued .

In the fully developed turbulent region for 0 < /Dcf < 0.03
Haaland (1983) gave the relation for friction factor as:
Schmitt and Kandlikar (2005) studied the effect of relative

roughness in artificially and roughened rectangular
microchannel.
They concluded that for shorter pitches, with pitch to
roughness ratios less than 5 the constricted model is able to
predict friction factor well. For higher, it approaches the
smooth channel value
10/25/2016
20
Roughness elements used

by Schmitt and Kandlikar
(2005)
10/25/2016
21
a) Fully developed friction factor, based

on hydraulic diameter for water flow
b) Fully developed friction factor, based

on constricted flow hydraulic diameter
for water flow
22
10/25/2016
Roughness effect on the

laminar-to-turbulent flow transition
For laminar to turbulence criteria:
10/25/2016
23
Heat Transfer in Microchannels

Fully developed laminar flow:
For fully
developed laminar flow Nusselt number is constant

depends on the channel geometry and wall heat transfer
boundary conditions.
For rectangular channel with aspect ratio c=a/b Nusselt
number is given as below:
Case 1: Constant wall temperature:
Case 2: Constant circumferential wall temperature and

uniform axial heat flux.
10/25/2016
24
Heat Transfer in Microchannels

Case3: Constant wall heat flux both circumferentially and
axially
Thermally developing flow:
Thermal entry length is given by:
For circular tube c = 0.05 and for rectangular tubes c = 0.1

The local Nusselt number in the developing region of a
circular tube is given by:
where,
10/25/2016
25
Agreement between theory and experimental

data on laminar heat transfer
Agreement with the
classical laminar ow
theory is expected to hold,
but the reported data show
signicant scatter.
The laminar ow heat

transfer in the fully
developed region is
expected to be constant,
but the data taken from
literature show a generally
linear increase in Nusselt
number with ow Reynolds
number as shown in figure.
10/25/2016
Experimental data for single phase liquid

flow in microchannels and minichannels
26
Agreement between theory and experimental

data on laminar heat transfer
The main reasons for this discrepancy have been

attributed to the following factors:
Entrance region effects
Variable property
Uncertainties in experimental measurements
Ambiguity in the determination of the thermal
boundary condition.
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27
Heat transfer in transition and turbulent flow

regions
For developing turbulent region:
For 0.5 Pr 1.5
For 1.5 Pr 500
For turbulent region:
where C = 7.6 e -5 and Do = 1.164 mm and NuGn is given by

Gnielinshis correlation.
10/25/2016
28
Axial Conduction Effects
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29
Variable Property Effects

The property ratio is used for accounting the variation in the
properties due to temperature.
Friction factor is given by:
Nusselt number is given by:

where, cp - refers to the constant property solution obtained
from appropriate equations.
For Laminar flow: M = 0.58 and N = -0.14
For Turbulent flow: M = 0.25 and N = -0.11
10/25/2016
30
Roughness Effect on heat transfer in

microchannels and minichannels
Kandlikar (2003) observed that the Nusselt number increases
with increase in the relative roughness.
The effect of roughness on Nu in the thermal entrance region with fully

developed velocity profile and a developing temperature profile
10/25/2016
31
Effect of Flow Maldistribution on Hydrodynamic and

Thermal Performance of Parallel Microchannel System
Experimental Setup:
Flow
Maldistri
bution
10/25/2016
32
Types of Test Sections

To study the effect of inlet outlet configurations U, Z, I
type of channels are considered.
U type of microchannel
I type of microchannel
Z type of microchannel
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33
Experimental Setup Schematic
Test Section
10/25/2016
Schematic of Experimental Set-up
34
Experimental Setup
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35
Method of preparation
Micro channel on Silicon wafer
Cleaned bare Si wafer
Oxide coating
PPR is coated and spinned over the surface
Mask is placed over the wafer and the
channel portion is exposed to UV radiation
PPR is removed by dipping the wafer in
dipping in KOH solution --- Developing
Coating PPR on the back side of wafer
Removing Oxide layer by BHF
Cleaning with Acetone
Etching by KOH
Removing Oxide layer by HF
10/25/2016
36
Size Effect- U type

d=88m, n=10, U type
d=176m, n=10, U type
10/25/2016
d=352m, n=10, U type
37
Size effect - Z and I type
d=88m, n=10, Z type
10/25/2016
d=88m, n=10, I type

38
Effect of Flow Configuration

Flow distribution improves with decrease in size of the
channel.
I type is having the least flow maldistribution.
d=88m, 352m, n=10 for U, Z, I type

10/25/2016
39
Effect of flow maldistribution on Temperature

for U type
Power Input = 9.2W, U type
Comparison of d=88m and d=176m
Mass flow rate is kept constant
10/25/2016
40
Effect of flow maldistribution on Temperature

for U type
Power Input = 30W, U type
Comparison of d=352m and d=176m
Mass flow rate is kept constant
10/25/2016
41
Influence of power input on the flow

maldistribution parameter
Flow maldistribution increases with power input due to
change in property of the fluid.
( Pm a x Pm in ) / Pm a x
10/25/2016
42
Microchannel and minichannel geometry

optimization
First practical implication of microchannels in silicon devices was
demonstrated by Tuckerman and Pease (1981).
They were able to dissipate 7.9 MW/m2 with a maximum substrate temperature
rise of 71C and a pressure drop of 186 kPa.
The allowable temperature differences and the pressure drops for cooling
todays microprocessor chips have become signicantly smaller.
Researchers have been working towards optimization of the channel
geometrical conguration.
Schematic view of the compact heat sink
incorporated into an integrated circuit chip. For a
1cm2 silicon IC using a water coolant, The
optimum dimensions are approximately ww = wc
= 57m and z = 365m
10/25/2016
43
THANK YOU
44
10/25/2016

Single Phase Liquid Flows in Microchannel

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ME 6004

MICRO AND NANOSCALE ENERGY

Dr. Arvind Pattamatta

Main Areas Currently Investigated

Dr. Arvind Pattamatta

Pressure Drop in Single-Phase Liquid Flow

Therefore, shear stress and pressure gradient are related as:

Dr. Arvind Pattamatta

Pressure Drop in Single-Phase Liquid Flow

Dr. Arvind Pattamatta

Fully Developed Laminar Flow

Dr. Arvind Pattamatta

Fully Developed Laminar Flow continued .

Dr. Arvind Pattamatta

Developing Laminar Flow

where, fapp accounts for pressure drop and the developing

Dr. Arvind Pattamatta

Developing Laminar Flow continued .

For x > Lh, incremental pressure attains the constant value

Shah and London(1972) given the equation for the pressure

Dr. Arvind Pattamatta

Developing Laminar Flow continued .

Dr. Arvind Pattamatta

Developing Laminar Flow continued .

Dr. Arvind Pattamatta

Fully developed and developing turbulent flow

where, Dle is the laminar-equivalent diameter.

Dr. Arvind Pattamatta

Total Pressure Drop in Microchannel Heat

Schematic representation of the experiments employed by

Dr. Arvind Pattamatta

Total Pressure Drop in Microchannel Heat Exchanger

Dr. Arvind Pattamatta

Total Pressure Drop in Microchannel Heat Exchanger

For L>Lh, K(x) is replaced by the Hagenbachs factor K()

Dr. Arvind Pattamatta

Laminar to Turbulent transition

Comparison between theory

Dr. Arvind Pattamatta

Average maximum prole peak height (Rpm): The distance

Dr. Arvind Pattamatta

Roughness Effects continued .

mean value of the spacing between prole irregularities within the

Floor distance to mean line (Fp): Consists of the distance

Dr. Arvind Pattamatta

Roughness Effects on friction factor

So a modified Moody diagram

Dr. Arvind Pattamatta

Constricted flow model

constricted flow diameter is given by:

Dr. Arvind Pattamatta

Constricted flow model continued .

Schmitt and Kandlikar (2005) studied the effect of relative

Dr. Arvind Pattamatta

Constricted flow model continued .

Roughness elements used

Dr. Arvind Pattamatta

Constricted flow model continued .

a) Fully developed friction factor, based

b) Fully developed friction factor, based

Dr. Arvind Pattamatta

Roughness effect on the

Dr. Arvind Pattamatta

Heat Transfer in Microchannels