Mohammad M. Hasan

Experimental assessment of the effects of body force, surface tension force, and inertia on flow boiling CHF

Abstract The interfacial instabilities important to the modeling of critical heat flux (CHF) in reduced-gravity systems are sensitive to even minute body forces, especially for small coolant velocities. Understanding these effects is of paramount importance to both the reliability and safety of two-phase thermal management loops proposed for future space and planetary-based thermal systems. Unfortunately, reduced gravity systems cannot be accurately simulated in 1g ground-based experiments. However, ground-based experiments can help isolate the effects of the various forces (body force, surface tension force and inertia) which influence flow boiling CHF. In this project, the effects of the component of body force perpendicular to a heated wall were examined by conducting 1g flow boiling experiments at different orientations. Boiling experiments were performed using FC-72 in vertical and inclined upflow and downflow, as well as horizontal flow, and with the heated surface facing upward or downward relative to gravity. CHF was very sensitive to orientation for flow velocities below 0.2 m/s and near-saturated flow; CHF values for downflow and downward-facing heated surface were much smaller than for upflow and upward-facing surface orientations. Increasing velocity and subcooling dampened the effects of flow orientation on CHF. For saturated flow, the vapor layer characteristics fell into six different regimes: wavy vapor layer, pool-boiling, stratification, vapor stagnation, vapor counterflow, and vapor concurrent flow. The wavy vapor layer regime encompassed all subcooled and high-velocity saturated conditions at all orientations, as well as low-velocity upflow orientations. Prior CHF correlations and models were compared, and shown to predict the CHF data with varying degrees of success.

Pressure Control Analysis of Cryogenic Storage Systems

This paper examines self-pressurization of cryogenic storage tanks due to heat leakage through the thermal protection system and the performance of various pressure control technologies intended for application in microgravity environments. Methods of pressure control such as fluid mixing, passive thermodynamic venting, and active thermodynamic venting are analyzed using the homogeneous thermodynamic model. The homogeneous model assumes that the liquid and vapor phases are at a uniform temperature equal to the saturation temperature of the cryogenic fluid at the total tank pressure. Simplified equations suggested in the paper may be used to characterize the performance of various pressure-control systems and to design space experiments for the development of low-gravity cryogenic fluid management technologies.

Experimental and theoretical study of orientation effects on flow boiling CHF

Abstract The effects of orientation on flow boiling critical heat flux (CHF) were investigated using high-speed video and microphotographic techniques. Interfacial features were measured just prior to CHF and statistically analyzed. A dominant wavy vapor layer regime was observed for all relatively high-velocities and most orientations, while several other regimes were encountered at low velocities, in downflow and/or downward-facing heated wall orientations. The interfacial lift-off model was modified and used to predict the orientation effects on CHF for the dominant wavy vapor layer regime. The photographic study revealed a fairly continuous wavy vapor layer travelling along the heated wall while permitting liquid contact only in wetting fronts, located in the troughs of the interfacial waves. The waves, which were generated at an upstream location, had a tendency to preserve a curvature ratio as they propagated along the heated wall. CHF commenced when wetting fronts near the outlet were lifted off the wall. This occurred when the momentum of vapor normal to the wall exceeded the pressure force associated with interfacial curvature. The interfacial lift-off model is shown to be very effective at capturing the overall dependence of CHF on orientation.

A Method for Assessing the Importance of Body Force on Flow Boiling CHF

Experiments were performed to examine the effects of body force on flow boiling CHF. FC-72 was boiled along one wall of a transparent rectangular flow channel that permitted photographic study of the vapor-liquid interface just prior to CHF High-speed video imaging techniques were used to identify dominant CHF mechanisms corresponding to different flow orientations and liquid velocities. Six different CHF regimes were identified: Wavy Vapor Layer, Pool Roiling, Stratification, Vapor Counterflow, Vapor Stagnation, and Separated Concurrent Vapor Flow. CHF showed significant sensitivity to orientation for flow velocities below 0.2 m/s, where extremely low CHF values where measured, especially with downward-facing heated wall and downflow orientations. High flow velocities dampened the effects of orientation considerably. The CHF data were used to assess the suitability of previous CHF models and correlations

Application of Flow Boiling for Thermal Management of Electronics in Microgravity and Reduced-Gravity Space Systems

Large density differences between liquid and vapor create buoyancy effects in the presence of a gravitational field. Such effects can play an important role in two-phase fluid flow and heat transfer, especially critical heat flux (CHF). CHF poses significant risk to electronic devices, and the ability to predict its magnitude is crucial to both the safety and reliability of these devices. Variations in the gravitational field perpendicular to a flow boiling surface can take several forms, from flows at different orientations at 1 ge to the microgravity environment of planetary orbit, to the reduced gravity on the Moon and Mars, and the high gs encountered in fighter aircraft during fast aerial maneuvers. While high coolant velocities can combat the detrimental effects of reduced gravity, limited power budget in space systems imposes stringent constraints on coolant flow rate. Thus, the task of dissipating the heat must be accomplished with the lowest possible flow velocity while safely avoiding CHF. In this study, flow-boiling CHF is investigated on Earth as well as in reduced gravity parabolic flight experiments using FC-72 as working fluid. CHF showed sensitivity to gravity at low velocities, with microgravity yielding significantly lower CHF values compared to those at 1 ge. Differences in CHF value decreased with increasing flow velocity until a velocity limit was reached above which the effects of gravity became inconsequential. This proves existing data, correlations, and models developed from 1 ge studies can be employed with confidence to design reduced gravity thermal management systems, provided the flow velocity is maintained above this limit. This study discusses two powerful predictive tools. The first, which consist of three dimensionless criteria, centers on determination of the velocity limit. The second is a theoretically based model for flow boiling CHF in reduced gravity below this velocity limit.

Self-pressurization of a flightweight liquid hydrogen tank - Effects of fill level at low wall heat flux

Experimental results are presented for the self pressurization and thermal stratification of a 4.89 cu m liquid hydrogen storage tank subjected to low heat flux (2.0 and 3.5 W/sq m) in normal gravity. The test tank was representative of future spacecraft tankage, having a low mass to volume ratio and high performance multilayer thermal insulation. Tests were performed at fill levels of 29 and 49 pcts. (by volume) and complement previous tests at 83 pct. fill. As the heat flux increases, the pressure rise rate at each fill level exceeds the homogeneous rate by an increasing ratio. Herein, this ratio did not exceed a value of 2. The slowest pressure rise rate was observed for the 49 pct. fill level at both heat fluxes. This result is attributed to the oblate spheroidal tank geometry which introduces the variables of wetted wall area, liquid-vapor interfacial area, and ratio of side wall to bottom heating as a function of fill level or liquid depth. Initial tank thermal conditions were found to affect the initial pressure rise rate. Quasi steady pressure rise rates are independent of starting conditions.

A Review of the Experimental and Modeling Development of a Water Phase Change Heat Exchanger for Future Exploration Support Vehicles

Water affords manifold benefits for human space exploration. Its properties make it useful for the storage of thermal energy as a Phase Change Material (PCM) in thermal control systems, in radiation shielding against Solar Particle Events (SPE) for the protection of crew members, and it is indisputably necessary for human life support. This paper envisions a single application for water which addresses these benefits for future exploration support vehicles and it describes recent experimental and modeling work that has been performed in order to arrive at a description of the thermal behavior of such a system. Experimental units have been developed and tested which permit the evaluation of the many parameters of design for such a system with emphasis on the latent energy content, temperature rise, mass, and interstitial material geometry. The experimental results are used to develop a robust and well correlated model which is intended to guide future design efforts toward the multi-purposed water PCM heat exchanger envisioned.

Convective Heat Transfer Coefficients for Near-Horizontal Two-Phase Flow of Nitrogen and Hydrogen at Low Mass and Heat Flux

Correlations for convective heat transfer coefficients are reported for two-phase flow of nitrogen and hydrogen under low mass and heat flux conditions. The range of flowrates, heat flux and tube diameter are representative of thermodynamic vent systems (TVSs) planned for propellant tank pressure control in spacecraft operating over long durations in microgravity environments. Experiments were conducted in normal gravity with a 1.5° upflow configuration. The Nusselt number exhibits peak values near transition from laminar to turbulent flow based on the vapor Reynolds number. This transition closely coincides with a flow pattern transition from plug to slug flow. The Nusselt number was correlated using components of the Martinelli parameter and a liquid-only Froude number. Separate correlating equations were fitted to the laminar liquid/laminar vapor and laminar liquid/turbulent vapor flow data. The correlations give root-mean-squared (rms) prediction errors within 15%.

Analysis of heat and mass transfer during condensation over a porous substrate

Abstract:  Condensing heat exchangers are important in many space applications for thermal and humidity control systems. The International Space Station uses a cooled fin surface to condense moisture from humid air that is blown over it. The condensate and the air are “slurped” into a system that separates air and water by centrifugal forces. The use of a cooled porous substrate is an attractive alternative to the fin where condensation and liquid/gas separation can be achieved in a single step. We analyze the heat and mass transfer during condensation of moisture from flowing air over such a cooled, flat, porous substrate. A fully developed regime is investigated for coupled mass, momentum and energy transport in the gas phase, and momentum and energy transport in the condensate layer on the porous substrate and through the porous medium.

Experimental Investigation of Flow Condensation in Microgravity

Future manned space missions are expected to greatly increase the space vehicles size, weight, and heat dissipation requirements. An effective means to reducing both size and weight is to replace single-phase thermal management systems with two-phase counterparts that capitalize upon both latent and sensible heat of the coolant rather than sensible heat alone. This shift is expected to yield orders of magnitude enhancements in flow boiling and condensation heat transfer coefficients. A major challenge to this shift is a lack of reliable tools for accurate prediction of two-phase pressure drop and heat transfer coefficient in reduced gravity. Developing such tools will require a sophisticated experimental facility to enable investigators to perform both flow boiling and condensation experiments in microgravity in pursuit of reliable databases. This study will discuss the development of the Flow Boiling and Condensation Experiment (FBCE) for the International Space Station (ISS), which was initiated in 2012 in collaboration between Purdue University and NASA Glenn Research Center. This facility was recently tested in parabolic flight to acquire condensation data for FC-72 in microgravity, aided by high-speed video analysis of interfacial structure of the condensation film. The condensation is achieved by rejecting heat to a counter flow of water, and experiments were performed at different mass velocities of FC-72 and water and different FC-72 inlet qualities. It is shown that the film flow varies from smooth-laminar to wavy-laminar and ultimately turbulent with increasing FC-72 mass velocity. The heat transfer coefficient is highest near the inlet of the condensation tube, where the film is thinnest, and decreases monotonically along the tube, except for high FC-72 mass velocities, where the heat transfer coefficient is enhanced downstream. This enhancement is attributed to both turbulence and increased interfacial waviness. One-ge correlations are shown to predict the average condensation heat transfer coefficient with varying degrees of success, and a recent correlation is identified for its superior predictive capability, evidenced by a mean absolute error of 21.7%.