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All sourcesNASA NTRSDOE OSTI
NASA NTRS2023

Effects of Heating Configuration and Operating Parameters on Heat Transfer and Interfacial Physics of Microgravity Flow Boiling With Subcooled Inlet Conditions –Experiments Onboard the International Space Station

This study is part of the Flow Boiling and Condensation Experiment (FBCE), a collaborative effort between the Purdue University Boiling and Two-Phase Flow Laboratory (PU-BTPFL) and the NASA Glenn Research Center. The FBCE fitted with the Flow Boiling Module (FBM) was launched to the International Space Station (ISS) in August 2021 and experiments were successfully performed from February to July 2022 to amass a large microgravity-flow-boiling database. This study is focused on heat transfer and flow visualization of microgravity flow boiling of n-Perfluorohexane in a rectangular channel of 5.0 mm height, 2.5 mm width (heated), and 114.6 mm length, with subcooled inlet conditions. High-speed-video photography is utilized to present flow patterns and temporal interfacial behavior. Heat transfer results are presented in the form of flow boiling curves and both parametric curves and streamwise profiles of wall temperature and heat transfer coefficient. Firstly, the parametric effects of mass velocity (199.4 – 3200.0 kg/m 2 s), inlet subcooling (0.2 – 46.0°C), and inlet pressure (124.2 – 176.7 kPa), on the aforementioned aspects are assessed for double-sided heating to establish them for a microgravity environment. Of these three parameters, mass velocity and inlet subcooling mostly determine the microgravity flow boiling behavior, while inlet pressure plays an insignificant role. Flow patterns for double-sided heating are more complex than those for single-sided heating due to interaction between the two vapor layers. Vapor interaction is minimized at high subcoolings and high mass velocities due to strong condensation offered by the subcooled bulk liquid layer separating them. Despite the different flow patterns, both single- and double-sided heating generally result in similar parametric trends and local heat transfer coefficients for similar operating conditions. Flow instabilities manifest as temporal flow anomalies and temperature oscillations, and their severity increases with increasing boiling number. Secondly, the effects of heating configuration are analyzed by comparing and contrasting several aspects of single- and double-sided heating data. The heat fluxes at which onset of nucleate boiling degradation (ONBD) and critical heat flux (CHF) occur are distinctly different for single- and double-sided heating. There exists a threshold inlet subcooling demarcating the dominance of flow acceleration and condensation effects in vapor removal from the near-wall region and replenishment of fresh liquid for boiling. Above the threshold, condensation from the near-wall region is dominant and single-sided heating yields higher heat fluxes, and below it, acceleration is dominant and double-sided yields higher heat fluxes. At mass velocity in the range of 200 – 2400 kg/m 2 s, the threshold inlet subcooling lies in the approximate range of 20 – 30°C (corresponding inlet quality of roughly -0.40 – -0.20).

Microgravity↗
DOE OSTI2016

High Resolution Measurements Reveal Transient Boiling Phenomena under Exponential Heat Inputs

Transient boiling heat transfer is important to the safety of nuclear reactors. Reactivity insertion accidents (RIA) in a nuclear reactor might result in a power excursion in which the heat generation in the fuel rises exponentially with time. The period of the exponential power excursion depends upon the magnitude of the reactivity insertion. The heat generated within the fuel is transferred to the water coolant which then starts to boil. The reactivity feedbacks caused by the heating (Doppler in the fuel and void in the coolant) represent an important mitigation mechanism for such accidents. The time delay between heat generation in the fuel and its transfer to the coolant is key to determining the outcome of the accident, in particular for experimental reactors using highly enriched fissile fuel with a very low Doppler effect. This time delay depends on conduction heat transfer within the fuel, single-phase convective heat transfer and eventually transient boiling heat transfer in the coolant. Although existing transient boiling databases form a highly valuable source of information, sometimes conclusions from different authors are quantitatively and qualitatively in disagreement with each other. This is likely due to differences in experimental setups and also limitations in the accuracy of diagnostics available in those experiments. In order to clarify these discrepancies and shed light on the mechanisms of transient boiling heat transfer, a new experimental study of both pool and flow boiling under exponential power input were carried out respectively. Exponential power escalation periods from 5 ms to 100 ms, bulk temperatures from saturation to 75 K of subcooling and Reynolds number from 25000 to 60000 have been explored at ambient pressure in both pool and flow boiling conditions. What makes this study unique is the use of synchronized state-of-the-art diagnostics such as IR thermometry and high speed video (HSV) which has improved the accuracy of measured quantities, and has provided a new and unique insights into the transient boiling heat transfer, including detection and modeling of the onset of nucleate boiling, better understanding of the transient boiling process and revelation of a new heat transfer mechanism that leads to higher CHF. (authors)

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
NASA NTRS1994

Transient nucleate pool boiling in microgravity: Some initial results

Variable gravity provides an opportunity to test the understanding of phenomena which are considered to depend on buoyancy, such as nucleate pool boiling. The active fundamental research in nucleate boiling has sought to determine the mechanisms or physical processes responsible for its high effectiveness, manifested by the high heat flux levels possible with relatively low temperature differences. Earlier research on nucleate pool boiling at high gravity levels under steady conditions demonstrated quantitatively that the heat transfer is degraded as the buoyancy normal to the heater surfaced increases. Correspondingly, it was later shown, qualitatively for short periods of time only, that nucleate boiling heat transfer is enhanced as the buoyancy normal to the heater surface is reduced. It can be deduced that nucleate pool boiling can be sustained as a quasi-steady process provided that some means is available to remove the vapor generated from the immediate vicinity of the heater surface. One of the objectives of the research, the initial results of which are presented here, is to quantify the heat transfer associated with boiling in microgravity. Some quantitative results of nucleate pool boiling in high quality microgravity (a/g approximately 10(exp -5)) of 5s duration, obtained in an evacuated drop tower, are presented here. These experiments were conducted as precursors of longer term space experiments. A transient heating technique is used, in which the heater surface is a transparent gold film sputtered on a qua rtz substrate, simultaneously providing the mean surface temperature from resistance thermometry and viewing of the boiling process both from beneath and across the surface. The measurement of the transient mean heater surface temperature permits the computation, by numerical means, of the transient mean heat transfer coefficient. The preliminary data obtained demonstrates that a quasi-steady boiling process can occur in microgravity if the bulk liquid subcooling is sufficiently high and if the imposed heat flux is sufficiently low. This is attributed to suface tension effects at the liquid-vapor-solid junction causing rewetting to take place, sustaining the nucleate boiling. Otherwise, dryout at the heater surface will occur, as observed.

Merte, Herman, Jr.↗
NASA NTRS1998

Bubble Dynamics, Two-Phase Flow, and Boiling Heat Transfer in Microgravity

This report contains two independent sections. Part one is titled "Terrestrial and Microgravity Pool Boiling Heat Transfer and Critical heat flux phenomenon in an acoustic standing wave." Terrestrial and microgravity pool boiling heat transfer experiments were performed in the presence of a standing acoustic wave from a platinum wire resistance heater using degassed FC-72 Fluorinert liquid. The sound wave was created by driving a half wavelength resonator at a frequency of 10.15 kHz. Microgravity conditions were created using the 2.1 second drop tower on the campus of Washington State University. Burnout of the heater wire, often encountered with heat flux controlled systems, was avoided by using a constant temperature controller to regulate the heater wire temperature. The amplitude of the acoustic standing wave was increased from 28 kPa to over 70 kPa and these pressure measurements were made using a hydrophone fabricated with a small piezoelectric ceramic. Cavitation incurred during experiments at higher acoustic amplitudes contributed to the vapor bubble dynamics and heat transfer. The heater wire was positioned at three different locations within the acoustic field: the acoustic node, antinode, and halfway between these locations. Complete boiling curves are presented to show how the applied acoustic field enhanced boiling heat transfer and increased critical heat flux in microgravity and terrestrial environments. Video images provide information on the interaction between the vapor bubbles and the acoustic field. Part two is titled, "Design and qualification of a microscale heater array for use in boiling heat transfer." This part is summarized herein. Boiling heat transfer is an efficient means of heat transfer because a large amount of heat can be removed from a surface using a relatively small temperature difference between the surface and the bulk liquid. However, the mechanisms that govern boiling heat transfer are not well understood. Measurements of wall temperature and heat flux near the wall would add to the database of knowledge which is necessary to understand the mechanisms of nucleate boiling. A heater array has been developed which contains 96 heater elements within a 2.5 mm square area. The temperature of each heater element is held constant by an electronic control system similar to a hot-wire anemometer. The voltage that is being applied to each heater element can be measured and digitized using a high-speed Analog to Digital (A/D) converter, and this digital information can be compiled into a series of heat-flux maps. Information for up to 10,000 heat flux maps can be obtained each second. The heater control system, the A/D system and the heater array construction are described in detail. Results are presented which show that this is an effective method of measuring the local heat flux during nucleate and transition boiling. Heat flux maps are obtained for pool boiling in FC-72 on a horizontal surface. Local heat flux variations are shown to be three to six times larger than variations in the spatially averaged heat flux.

Chung, Jacob N.↗
NASA NTRS1999

Experimental Investigation of Pool Boiling Heat Transfer Enhancement in Microgravity in the Presence of Electric Fields

In boiling high heat fluxes are possible driven by relatively small temperature differences, which make its use increasingly attractive in aerospace applications. The objective of the research is to develop ways to overcome specific problems associated with boiling in the low gravity environment by substituting the buoyancy force with the electric force to enhance bubble removal from the heated surface. Previous studies indicate that in terrestrial applications nucleate boiling heat transfer can be increased by a factor of 50, as compared to values obtained for the same system without electric fields. The goal of our research is to experimentally explore the mechanisms responsible for EHD heat transfer enhancement in boiling in low gravity conditions, by visualizing the temperature distributions in the vicinity of the heated surface and around the bubble during boiling using real-time holographic interferometry (HI) combined with high-speed cinematography. In the first phase of the project the influence of the electric field on a single bubble is investigated. Pool boiling is simulated by injecting a single bubble through a nozzle into the subcooled liquid or into the thermal boundary layer developed along the flat heater surface. Since the exact location of bubble formation is known, the optical equipment can be aligned and focused accurately, which is an essential requirement for precision measurements of bubble shape, size and deformation, as well as the visualization of temperature fields by HI. The size of the bubble and the frequency of bubble departure can be controlled by suitable selection of nozzle diameter and mass flow rate of vapor. In this approach effects due to the presence of the electric field can be separated from effects caused by the temperature gradients in the thermal boundary layer. The influence of the thermal boundary layer can be investigated after activating the heater at a later stage of the research. For the visualization experiments a test cell was developed. All four vertical walls of the test cell are transparent, and they allow transillumination with laser light for visualization experiments by HI. The bottom electrode is a copper cylinder, which is electrically grounded. The copper block is heated with a resistive heater and it is equipped with 6 thermocouples that provide reference temperatures for the measurements with HI. The top electrode is a mesh electrode. Bubbles are injected with a syringe into the test cell through the bottom electrode. The working fluids presently used in the interferometric visualization experiments, water and PF 5052, satisfy requirements regarding thermophysical, optical and electrical properties. A 30kV power supply equipped with a voltmeter allows to apply the electric field to the electrodes during the experiments. The magnitude of the applied voltage can be adjusted either manually or through the LabVIEW data acquisition and control system connected to a PC. Temperatures of the heated block are recorded using type-T thermocouples, whose output is read by a data acquisition system. Images of the bubbles are recorded with 35mm photographic and 16mm high-speed cameras, scanned and analyzed using various software packages. Visualized temperature fields HI allows the visualization of temperature fields in the vicinity of bubbles during boiling in the form of fringes. Typical visualized temperature distributions around the air bubbles injected into the thermal boundary layer in PF5052 are shown. The temperature of the heated surface is 35 C. The temperature difference for a pair of fringes is approximately 0.05 C. The heat flux applied to the bottom surface is moderate, and the fringe patterns are regular. In the image a bubble penetrating the thermal boundary layer is visible. Because of the axial symmetry of the problem, simplified reconstruction techniques can be applied to recover the temperature field. The thermal plume developing above the heated surface for more intensive heating is shown. The temperature distribution in the liquid is clearly 3D, and tomographic techniques have to be applied to recover the temperature distribution in such a physical situation. A sequence of interferometric images showing the temperature distribution around the rising bubble, recorded with a high-speed camera is shown. Again, the temperature distribution is 3D, and a more complex approach to the evaluation, the tomographic reconstruction has to be taken. Measurement of the temperature distribution from the fringe pattern temperature distributions that yield important information regarding heat transfer are determined. Two algorithms that allow the quantitative evaluation of interferometric fringe patterns and the reconstruction of temperature fields during boiling have been developed at the Heat Transfer Laboratory of the Johns Hopkins University. In the first algorithm the bubble is assumed to be axially symmetrical, which significantly reduces the computational effort for quantifying the temperature distribution around the bubble. For this purpose the thermal boundary layer around the bubble is divided into equidistant concentric shells, and the refractive index is assumed to be constant in each of the shells. Since large temperature gradients are expected in the vicinity of the bubble during boiling, the deflection of the light beam cannot be neglected in boiling experiments. Since the exit angle of the light beam is known, this allows to account for the deflections and phase shifts outside the boundary layer (in the bulk fluid and in the windows of the test cell). Three dimensional temperature distributions in the vicinity of the bubble are reconstructed using tomographic techniques. In tomography, the measurement volume is sliced into 2D planes. In the present study these planes are parallel to the heated surface. The objective is to determine the values of the field parameter of interest in form of the field function in these 2D planes. The field parameter is the change of the refractive index of the liquid in the measurement volume caused by temperature changes. By superimposing data for many 2D planes recorded at the same time instant, the 3D temperature distribution in the measurement volume is recovered.

Herman, Cila↗
NASA NTRS2000

Marangoni Effects on Near-Bubble Microscale Transport During Boiling of Binary Fluid Mixtures

In earlier investigations, Marangoni effects were observed to be the dominant mechanism of boiling transport in 2-propanol/water mixtures under reduced gravity conditions. In this investigation we have examined the mechanisms of binary mixture boiling by exploring the transport near a single bubble generated in a binary mixture between a heated surface and cold surface. The temperature field created in the liquid around the bubble produces vaporization over the portion of its interface near the heated surface and condensation over portions of its interface near the cold surface. Experiments were conducted using different mixtures of water and 2-propanol under 1g conditions and under reduced gravity conditions aboard the KC135 aircraft. Since 2-propanol is more volatile than water, there is a lower concentration of 2-propanol near the hot surface and a higher concentration of 2-propanol near the cold plate relative to the bulk quantity. This difference in interface concentration gives rise to strong Marangoni effects that move liquid toward the hot plate in the near bubble region for 2-propanol and water mixtures. In the experiments in this study, the pressure of the test system was maintained at about 5 kPa to achieve the full spectrum of boiling behavior (nucleate boiling, critical heat flux and film boiling) at low temperature and heat flux levels. Heat transfer data and visual documentation of the bubble shape were extracted from the experimental results. In the 1-g experiments at moderate to high heat flux levels, the bubble was observed to grow into a mushroom shape with a larger top portion near the cold plate due to the buoyancy effect. The shape of the bubble was somewhat affected by the cold plate subcooling and the superheat of the heated surface. At low superheat levels for the heated surface, several active nucleation sites were observed, and the vapor stems from them merged to form a larger bubble. The generation rate of vapor is moderate in this regime and the bubble shape is cylindrical in appearance. In some instances, the bubble interface appeared to oscillate. At higher applied heat flux levels, the top of the bubble became larger, apparently to provide more condensing interface area adjacent to the cold plate. Increasing the applied heat flux ultimately led to dry-out of the heated surface, with conditions just prior to dryout corresponding to the maximum heat flux (CHF). A more stable bubble was observed when the system attained the minimum heat flux (for film boiling). In this regime, most of the surface under the bottom of the bubble was dry with nucleate boiling sometimes occuring around the contact perimeter of the bubble at heated surface. Different variations (e.g. gap between two plates, molar concentration of the liquid mixture) of the experiments were examined to determine parametric effects on the boiling process and to determine the best conditions for the KC135 reduced gravity tests. Variation of the gap was found to have a minor impact on the CHF. However, reducing the gap between the hot and cold surface was observed to significantly reduce the minimum heat flux for fixed molar concentration of 2-propanol. In the reduced gravity experiments aboard the KC135 aircraft, the bubble formed in the 6.4 mm gap was generally cylindrical or barrel shaped and it increased its extent laterally as the surface superheat increased. In reduced gravity experiments, dryout of the heated surface under the bubble was observed to occur at a lower superheated temperature than for 1g conditions. Observed features of the boiling process and heat transfer data under reduced gravity will be discussed in detail. The results of the reduced gravity experiments will also be compared to those obtained in comparable 1g experiments. In tandem with the experiments we are also developing a computational model of the transport in the liquid surrounding the bubble during the boiling process. The computational model uses a level set method to model motion of the interface. It will incorporate a macroscale treatment of the transport in the liquid gap between the surfaces and a microscale treatment of transport in the regions between the bubble interface and the solid surfaces. The features of the model will be described in detail. Future research directions suggested by the results to date will also be discussed.

V. Carey↗
NASA NTRSDate not supplied

Mini-Channel Flow Boiling in 1g and μg

Subcooled flow boiling combines complex processes governed by a strong coupling of heat and mass transfer, hydrodynamics, and liquid-vapor transitions. The gravitational body force plays an important role in these processes. By exploiting the latent heat of vaporization, subcooled flow boiling can transfer up to several orders-of-magnitude more heat compared to forced liquid flow. It is widely used in Earth-based thermal equipment to reduce the cost, size, and power required to move heat. Subcooled flow boiling is now considered a promising technology for space applications since it offers a means to control the motion of bubbles near the heated surface and thereby enhance nucleate boiling. However, a lack of data and predictive models on the role that gravity plays in these phenomena hinders the use of flow boiling in a microgravity environment. We will present results of experiments on transients in nucleate boiling that were carried out in the Flow Boiling Module (FBM) on the International Space Station (ISS). The unique ISS FBM ability is to couple large heat loads with flow visualization in testing flow boiling under strict control of experimental conditions in long-duration microgravity. Comparison of results of microgravity experiments with data obtained in a similar setup on the NASA GRC demonstrates the role of gravity in nucleate boiling. The work is supported by the NASA Flight Opportunities program (grant 80NSSC21K0501) and NSF/CASIS program (NSF CBET grants 1832260, 2126461, 2126462).

Two-phase flow and phase transition↗
DOE OSTI2018

Evaluation of DNB Predictive Capability in Multiphase Boiling Model of STAR-CCM+

The current milestone report is to evaluate the predictive capability of the existing boiling model in the commercial Computational Fluid Dynamics (CFD) package (so called, STARCCM+ 11.04.012), and validate the numerical calculation of a boiling curve with identification of departure from nucleate boiling (DNB) point by comparing with experimental measurements in the literatures. The current work directly demonstrates the DNB predictive capability in multiphase boiling model for nuclear reactor applications, which is tightly coupled with the CASL mission goal and evolving need from the nuclear industry. The boiling model tested here is based on the heat flux partitioning RPI approach (so called Generation-I boiling model in STAR-CCM+). A traditional experimental DNB test with a vertical pipe flow performed by Argonne National Laboratory (ANL), and a realistic 5x5-bundle fuel bundle with non-mixing vane DNB test conducted by Westinghouse Electric Company (WEC) are selected as reference experimental measurement. A baseline DNB simulation methodology is reported and its predictive capability is evaluated qualitatively as well as quantitatively with existing experiments. A parametric study of the microscopic boiling closure relations is investigated. For the pipe flow DNB validation study, the calculated DNB from the current study demonstrates good agreement with measured DNB data. The maximum deviation is observed less than 20%. The trend behaviors of DNB in varying operating conditions are similar with the observation reported in the literature. In addition, a meshing strategy for 5x5 bundle case is reported, some challenges on 5x5 bundle DNB model are also discussed. The current study provide a fundamental insight on the usefulness and limitations of the generation-I boiling model approach and may contribute to an advanced boiling model development for a practical nuclear thermal hydraulic application.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
NASA NTRS2022

Experimental Heat Transfer Results and Flow Visualization of Vertical Upflow Boiling in Earth Gravity with Subcooled Inlet Conditions – In Preparation for Experiments Onboard the International Space Station

Since 2012, researchers at the Purdue University Boiling and Two-Phase Flow Laboratory (PU-BTPFL) and NASA Glenn Research Center have been collaborating on a long-term effort to study flow boiling and condensation in microgravity. The ultimate goal has been to develop the Flow Boiling and Condensation Experiment (FBCE) for the International Space Station (ISS). Based on the findings from prior flow boiling experiments both at different orientations in Earth gravity and onboard parabolic flights simulating short durations of microgravity, a final refined experiment design, construction, and operating procedure have been arrived at for long-duration microgravity flow boiling experiments onboard the ISS. This study investigates flow boiling of n-Perfluorohexane with subcooled inlet in a rectangular channel of dimensions 114.6 mm heated length, 2.5 mm width, and 5 mm height. These pre-launch experiments (Mission Sequence Testing) were conducted in vertical upflow orientation in Earth gravity using the same experimental rig that was launched to the ISS in August 2021. The various operating parameters varied are heating configuration (single- and double-sided), mass velocity (180 – 3200 kg/m2s), inlet subcooling (+0 – 32°C, encompassing both highly subcooled and near-saturated inlet conditions), and inlet pressure (119 – 191 kPa). High-speed video flow visualization images are presented to explain the two-phase interfacial physics within the channel’s heated section. Heat transfer results in terms of flow boiling curves, streamwise profiles of wall temperature and heat transfer coefficient, and averaged heat transfer coefficients are analyzed and parametric effects elucidated. Severe temporal thermodynamic equilibrium is observed for near-saturated inlet at very low velocities. Nucleate boiling degradation starts at larger heat fluxes for single-sided heating than double sided at low mass velocities with highly subcooled inlet, and conversely at high mass velocities with near-saturated inlet. Nucleate boiling degradation can be delayed to higher heat fluxes by highly subcooling the inlet and increasing mass velocity. The entire local heat transfer coefficient profiles are degraded at higher heat fluxes for near-saturated inlet, but only the downstream part for highly subcooled inlet. This study also confirmed reliability of the upcoming ISS experimental data for subcooled inlet conditions and the collected Earth-gravity data will be used for comparison against the ISS data.

flow boiling↗
NASA NTRS2023

Cryogenic Flow Boiling in Microgravity: Effects of Reduced Gravity on Two-Phase Fluid Physics and Heat Transfer

With the growing interest in space exploration, cryogenic technologies involving two-phase flow and heat transfer are in high demand to successfully procure advanced space applications such as fuel depots and nuclear thermal propulsion (NTP) systems for deep space missions. However, the unique and extreme thermal properties of cryogenic fluids introduce distinct flow boiling fluid physics and energy transport phenomena, which differ significantly from those observed with conventional fluids. Understanding the unique two-phase physics in cryogenic flow boiling remains an ongoing challenge. Furthermore, the lack of readily available microgravity cryogenic steady-state heat transfer data hinders the assessment of gravitational effects on cryogenic flow boiling. This study aims to elucidate the gravitational effects on two-phase fluid physics and heat transfer by conducting the first-ever experimental measurement of cryogenic flow boiling performance using a steady-state heated method in a reduced gravity environment. Parabolic flight experiments were performed to acquire both heat transfer measurements and high-speed video of interfacial behaviors, under varying gravity levels (microgravity, hypergravity, Lunar gravity, and Martian gravity). The experiments involved flow boiling of liquid nitrogen (LN 2 ) with a near-saturated inlet along a circular heated tube of dimensions 8.5-mm inner diameter and 680-mm heated length. The operating parameters varied are mass velocity of 398.3 - 1342.8 kg/m2s, inlet quality of -0.08 to -0.01, and inlet pressure of 413.68 - 689.48 kPa. Captured microgravity flow patterns range from bubbly to annular, all having vapor structures that are larger than those under higher gravity levels. Under microgravity, absence of buoyancy yields symmetrical vapor structures without flow stratification, laying a physical foundation for the distinct two-phase heat transfer trends during LN 2 flow boiling in microgravity. Transient data collected during the flight parabolas exhibited decreasing heated wall temperature as the aircraft transitioned from hypergravity to microgravity phases. The temperature variation indicated an enhancement in flow boiling heat transfer with decreasing gravity levels and a reduction with increasing gravity levels. The effect of reduced gravity on cryogenic flow boiling heat transfer coefficient (HTC) is discussed based on steady state heat transfer analysis. Seminal HTC correlations are evaluated against the measured microgravity HTC data, of which one is identified for superior accuracy in predicting microgravity data. Finally, a new HTC correlation is proposed to improve accuracy of microgravity predictions, yet there still exists room for further improvement with future terrestrial flow boiling experiments at different flow orientations relative to Earth gravity.

Microgravity↗
DOE OSTI2024

The Onset of Nucleate Boiling Prediction in a Mini Channel with the Eulerian Multiphase Flow

The prediction of boiling incipience is a critical issue for a reactor. Vapor lock causes operating instability and undesirable temperature rise, especially for small channels. This study uses the Eulerian multiphase flow boiling model to predict the onset of nucleate boiling in a millimeter scale rectangular channel. Two wall boiling models, namely the RPI (Rensselaer Polytechnic Institute) and the non-equilibrium sub cooled model are applied. Computational fluid dynamics is employed for this study to investigate the impact of operating conditions like liquid flow rate, operating pressure, heat flux, velocity profile, turbulence model, and inlet liquid temperature. Here, the effect of fundamental boiling parameters on the surface wall temperature and vapor volume fraction is also studied. The parameters under consideration are the bubble departure diameter, bubble departure frequency, nucleate site density, quenching time period, and interface heat transfer coefficients. A series of CFD calculations is conducted by varying the considered variables systematically in a wide range of flow conditions covering laminar, transition, and turbulent flows. The sub-component heat fluxes like the liquid convective, the vapor convective, the evaporative, and the quenching terms are monitored to infer the boiling dynamics in the transition region from the single-phase flow to the nucleate boiling zone. It is found that the CFD approach to detecting the boiling incipience point agrees reasonably with available experimental data. However, its limitations, like inaccuracy for lower flow rates and early transition to boiling flow, are also noticed due to the nature of the considered RPI model.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2023

A unifying criterion of the boiling crisis

Abstract We reveal and justify, both theoretically and experimentally, the existence of a unifying criterion of the boiling crisis. This criterion emerges from an instability in the near-wall interactions of bubbles, which can be described as a percolation process driven by three fundamental boiling parameters: nucleation site density, average bubble footprint radius and product of average bubble growth time and detachment frequency. Our analysis suggests that the boiling crisis occurs on a well-defined critical surface in the multidimensional space of these parameters. Our experiments confirm the existence of this unifying criterion for a wide variety of boiling surface geometries and textures, two boiling regimes (pool and flow boiling) and two fluids (water and liquid nitrogen). This criterion constitutes a simple mechanistic rule to predict the boiling crisis, also providing a guiding principle for designing boiling surfaces that would maximize the nucleate boiling performance.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
NASA NTRS1972

A review of film boiling at cryogenic temperatures.

Film boiling occurs in the quenching of metals, the chilling of biological species, the regenerative cooling of rockets, and the cooling down of a cryogenic fuel tank. Occasionally film boiling is also found in a nuclear reactor or in a cryomagnet. Aspects of film boiling involving an unconstrained liquid mass are considered, giving attention to the evaporation time, the Leidenfrost temperature, solid-liquid contacts, the thermal properties of the solid, effects of coating or scale, wettability, the metastable condition, and the velocity effect on drops. Developments discussed with regard to pool boiling are related to vertical surfaces, film boiling from horizontal surfaces, film boiling from a horizontal cylinder, film boiling from a sphere, and film boiling of helium. Processes of film boiling in a channel are also analyzed.

Hsu, Y. Y.↗
NASA NTRS1991

A fundamental study of nucleate pool boiling under microgravity

An experimental study of incipient boiling in short-term microgravity and with a/g = +/- 1 for pool boiling was performed. Calibrated thin gold films sputtered on a smoothly polished quartz surface were used simultaneously for thermal resistance measurements and heating of the boiling surface. The gold films were used for both transient and quasi-steady heating surface temperature measurements. Two test vessels were constructed for precise measurement and control of fluid temperature and pressure: a laboratory pool boiling vessel for the a/g = +/- experiments and a pool boiling vessel designed for the 131 m free-fall in the NASA Lewis Research Center Microgravity Research Facility for the microgravity tests. Measurements included the heater surface temperature, the pressure near the heating surface, and the bulk liquid temperatures. High speed photography was used in the experiments. With high quality microgravity and the measured initial temperature of the quiescent test fluid, R113, the temperature distribution in the liquid at the moment of boiling inception resulting from an imposed step in heat flux is known with a certainty not possible previously. The types of boiling propagation across the large flat heating surface are categorized; the conditions necessary for their occurrence are described. Explosive boiling propagation with a striking pattern of small scale protuberances over the entire vapor mass periphery not observed previously at low heat flux levels is described. For the heater surface with a/g = -1, a step in the heater surface temperature of short duration was imposed. The resulting liquid temperature distribution at the moment of boiling inception was different from that obtained with a step in heat flux.

Ervin, Jamie S.↗
NASA NTRS1993

Nucleate pool boiling in the long duration low gravity environment of the Space Shuttle

The results are presented of an experimental study of nucleate pool boiling performed in the low gravity environment of the space shuttle. Photographic observations of pool boiling in Freon 113 were obtained during the 'Tank Pressure Control Experiment,' flown on the Space Transportation System, STS-43 in August 1991. Nucleate boiling data from large (relative to bubble size) flat heating surfaces (0.1046 by 0.0742 m) was obtained at very low heat fluxes (0.22 to 1.19 kW/sq m). The system pressure and the bulk liquid subcooling varied in the range of 40 to 60 kPa and 3 to 5 C respectively. Thirty-eight boiling tests, each of 10-min duration for a given heat flux, were conducted. Measurements included the heater power, heater surface temperature, the liquid temperature and the system pressure as functions of heating time. Video data of the first 2 min of heating was recorded for each test. In some tests the video clearly shows the inception of boiling and the growth and departure of bubbles from the surface during the first 2 min of heating. In the absence of video data, the heater temperature variation during heating shows the inception of boiling and stable nucleate boiling. During the stable nucleate boiling, the wall superheat varied between 2.8 to 3.8 C for heat fluxes in the range of 0.95 to 1.19 kW/sq m. The wall superheat at the inception of boiling varied between 2 to 13 C.

Hasan, M. M.↗
NASA NTRS1993

Nucleate pool boiling in the long duration low gravity environment of the space shuttle

The results are presented of an experimental study of nucleate pool boiling performed in the low gravity environment of the space shuttle. Photographic observations of pool boiling in Freon 113 were obtained during the 'Tank Pressure Control Experiment', flown on the Space Transportation System STS-43 in August 1991. Nucleate boiling data from large (relative to bubble size) flat heating surfaces (0.1046 by 0.0742 m) was obtained at very low heat fluxes (0.22 to 1.19 kw/so m). The system pressure and the bulk liquid subcooling varied in the range of 40 to 60 kPa and 3 to 5 C respectively. Thirty-eight boiling tests, each of 10 min duration for a given heat flux, were conducted. Measurements included the heater power, heater surface temperature, the liquid temperature and the system pressure as functions of heating time. Video data of the first 2 min of heating was recorded for each test. In some tests the video clearly shows the inception of boiling and the growth and departure of bubbles from the surface during the first 2 min of heating. In the absence of video data, the heater temperature variation during heating shows the inception of boiling and stable nucleate boiling. During the stable nucleate boiling, the wall superheat varied between 2.8 to 3.8 C for heat fluxes in the range of 0.95 to 1.19 kw/so m. The wall superheat at the inception of boiling varied between 2 to 13 C.

Hasan, M. M.↗
NASA NTRS1996

A Fundamental Study of Nucleate Pool Boiling Under Microgravity

An experimental study of incipient boiling in short-term microgravity and with a/g = +/- 1 for pool boiling was performed. Calibrated thin gold films sputtered on a smoothly polished quartz surface were used simultaneously for thermal-resistance measurements and heating of the boiling surface. The gold films were used for both transient and quasi-steady heating surface temperature measurements. Two test vessels were constructed for precise measurement and control of fluid temperature and pressure: a laboratory pool boiling vessel for the a/g = +/- 1 experiments and a pool boiling vessel designed for the 131 m free-fall in the NASA Lewis Research Center Microgravity Research Facility for the microgravity tests. Measurements included the heater surface temperature, the pressure near the heating surface, the bulk liquid temperatures. High speed photography (up to 1,000 frames per second) was used in the experiments. With high quality microgravity and the measured initial temperature of the quiescent test fluid, R113, the temperature distribution in the liquid at the moment of boiling inception resulting from an imposed step in heat flux is known with a certainty not possible previously. The types of boiling propagation across the large flat heating surface, some observed here for the first time, are categorized; the conditions necessary for their occurrence are described. Explosive boiling propagation with a striking pattern of small scale protuberances over the entire vapor mass periphery not observed previously at low heat flux levels (on the order of 5 W/cm(exp 2)) is described. For the heater surface with a/g = -1, a step in the heater surface temperature of short duration was imposed. The resulting liquid temperature distribution at the moment of boiling inception was different from that obtained with a step in heat flux.

Ervin, Jamie S.↗
NASA NTRS2001

Zero Boil Off Cryogen Storage for Future Launchers

Zero boil off (ZBO) cryogen storage using both cryocoolers and passive insulation technologies will enable long-term exploration missions by allowing designers to optimize tankage without the need for excess cryogen storage to account for boil off. Studies of ZBO (zero boil off) have been on-going in the USA for several years. More recently, a review of the needs of advanced space propulsion took place in Europe. This showed the interest of the European community in cryogenic propulsion for planetary missions as well as the use of liquid hydrogen for large power electric propulsion (manned Mars missions). Although natural boiling could be acceptable for single leg missions, passive insulation techniques yield roughly a I% per month cryogen loss and this would not be cost effective for robotic planetary missions involving storage times greater than one year. To make economic sense, long-term exploration missions require lower tank capacity and longer storage times. Recent advances in cryocooler technology, resulting in vast improvements in both cooler efficiency and reliability, make ZBO is a clear choice for planetary exploration missions. Other, more near term applications of ZBO include boil-off reduction or elimination applied to first and upper stages of future earth-to-orbit (ETO) launchers. This would extend launch windows and reduce infrastructure costs. Successors to vehicles like Ariane 5 could greatly benefit by implementing ZBO. Zero Boil Off will only be successful in ETO launcher applications if it makes economic sense to implement. The energy cost is only a fraction of the total cost of buying liquid cryogen, the rest being transportation and other overhead. Because of this, higher boiling point cryogens will benefit more from on-board liquefaction, thus reducing the infrastructure costs. Since hydrogen requires a liquefier with at least a 17% efficiency just to break even from a cost standpoint, one approach for implementing ZBO in upper stages would be to actively cool the shield in the hydrogen tank to reduce the parasitic losses. This would allow the use of less expensive, presently available coolers (80 K vs. 20 K) and potentially simplify the system by requiring only a single compressor on the pad amd a single disconnect line. The compressor could be a hefty commercial unit, with only the cold head requiring expensive flight development and qualification. While this is actually a reduced boil off configuration rather than a zero-boil off case, if the cryogen loss could be cut significantly, the increase in hold time and reduced need for draining and refilling the propellant tanks could meet the vehicle operations needs in the majority of instances.Bearing in mind the potential benefits of ZBO, NASA AMES and SNECMA Moteurs decided to exchange their technical views on the subject. This paper will present a preliminary analysis for a multi-mission module using a fairly low thrust cryogenic engine and ZBO during cruise. Initial mass is 5.5. tons (in ETO). The cryogenic engine will be used near each periapsis in order to minimize the AV requirement. The payload obtained by this propulsion system is compared to a classical storable bipropellant propulsion system for several cases (e. g. Mars lander, Jupiter orbiter, Saturn orbiter). For the Jupiter and Saturn cases, the power source could be an RTG or a large parabolic mirror illuminating a solar panel. It is shown -that - due to its much larger specific impulse - the cryogenic ZBO solution provides much higher payloads, especially for exploration missions involving landing on planets, asteroids, comets, or other celestial bodies.

Valentian, D.↗