Y. S. Muzychka Professor Mem. ASME Faculty of Engineering and Applied Science, Memorial University of Newfoundland, St. John’s, NL, A1B 3X5, Canada E. J. Walsh Senior Research Fellow Mem. ASME P. Walsh Senior Research Fellow Mem. ASME Stokes Research Institute, University of Limerick, Castletroy, County Limerick, Ireland 1 Heat Transfer Enhancement Using Laminar Gas-Liquid Segmented Plug Flows Heat transfer enhancement using segmented nonboiling gas-liquid flow is examined. Segmentation results in a two phase flow of liquid/gas having a constant liquid fraction; i.e., no phase change occurs. In this flow configuration, enhanced heat transfer occurs as a result of a shorter effective thermal length due to internal fluid circulation in the liquid plugs. A simple theory for laminar segmented flows is developed based on scaled Graetz theory and comparisons made with existing published data from the literature and new experimental data obtained in a companion study. The proposed model is valid for an isothermal tube wall provided that the axial residence time of the flow is such that dimensionless tube length L쐓 ⬍ 0.1. 关DOI: 10.1115/1.4002807兴 Keywords: heat transfer, segmented flow, two phase flow, thermal enhancement, Graetz flow, plug flow, Poiseuille flow, Taylor flow Introduction This present study examines the potential of heat transfer enhancement using uniformly segmented fluid streams. Such streams are frequently referred to as Taylor flows 关1兴 after Taylor’s original study 关2兴 of a simple two phase plug flow, Bolus flow 关3兴 in one of the earliest such studies involving heat transfer in a laminar two phase plug flow, and segmented flows 关4兴. Segmented flows find many applications in mass transfer systems where enhanced radial transport is desired while axial dispersion is minimized. A segmented fluid stream may be easily produced by using plugs of solid, liquid, or gas introduced into a liquid stream, denoted here as the carrier fluid, to which heat is to be transferred. In these cases, a two phase flow stream of alternating elements of segmenting media and carrier fluid are produced. The easiest such system to work with is the two phase gas-liquid system. A distinction is made between the traditional two phase plug 共or slug兲 flow and segmented flow for the following reasons. In a traditional two phase plug flow, the liquid plugs may not all be of uniform length, shape, and distribution, and as such, the fluid stream is much more complex and less amenable to theoretical analysis. In a uniformly segmented flow, both the liquid plugs in the carrier fluid and segmenting media have constant lengths and uniform spacing or frequency. Further, the segmenting media may or may not contribute significantly to the overall heat transfer rate. In this present study, we are considering only uniformly distributed gas-liquid segmented flows, as shown in Fig. 1. Segmented flows, while simple in composition, have many issues that must be considered, which affect heat transfer rates. These include • • • • • • • • thermal boundary condition type of velocity distribution plug length plug circulation liquid fraction liquid properties film evaporation duct shape Contributed by the Heat Transfer Division of ASME for publication in the JOURHEAT TRANSFER. Manuscript received May 6, 2009; final manuscript received September 25, 2010; published online January 11, 2011. Assoc. Editor: S. A. Sherif. NAL OF Journal of Heat Transfer Early studies in two phase plug flow hypothesized that enhancement in heat transfer rates in laminar flows could be obtained by splitting up the coolant stream into a series of shorter elements or plugs 关3–8兴. These early studies in two phase flow heat transfer considered thermal enhancement using gas or solid plugs as a segmenting medium. It has long been known that within the liquid plugs, internal circulations arise as a result of the gas-liquid, solid-liquid, or liquid-liquid interfaces 关1,2,4–8兴. It has been hypothesized that thermal enhancement occurs due to two effects. One is a result of the internal circulation in the liquid plugs, leading to greater radial transport of heat or mass, while the other mechanism results from the increased velocity that liquid plugs experience as a result of the reduced liquid fraction for a constant mass flow rate. The latter will be shown to be unlikely using simple heat transfer theory. This leaves only plug circulation effects and/or general plug velocity distribution as the primary effect contributing to enhanced heat transfer. A number of these early works have also attempted to predict the two phase plug flow data using the single phase Graetz solution for a tube 关3–9兴. Each of these studies failed to successfully show any correlation with the Graetz theory but showed increased heat transfer rates for segmented flows having the same mass flow rate as compared with a continuous flow stream. While these studies carefully examined the effect of void fraction and plug length on heat transfer enhancement using carefully planned experiments, they failed to consider plug length as an actual scaling parameter in heat transfer predictions. The data from these and other studies are re-analyzed using different scaling principles in the present work. Three early studies considered in this work are those of Horvath et al. 关4兴, Oliver and Young-Hoon 关6,7兴, and Vrentas et al. 关8兴. In all three studies, the authors made attempts to relate single phase heat transfer theory to either predict or show the level of enhancement in Nusselt data versus some reference parameter that was usually taken as the Reynolds number, the Graetz number, or the Peclet number of the actual flow. In all cases when the Graetz– Leveque model was compared with experimental data, the authors used the total heated tube length in their data reduction for defining the dimensionless thermal length and invariably used the total or wetted surface area of the tube when determining Nusselt numbers. It is this inconsistency in addition to the definitions of Nusselt number and Reynolds number that leads to the ultimate failure in correlating these carefully obtained experimental plug flow data using the classic Graetz flow theory. Copyright © 2011 by ASME APRIL 2011, Vol. 133 / 041902-1 Downloaded 16 Mar 2011 to 134.153.184.170. Redistribution subject to ASME license or copyright; see http://www.asme.org/terms/Terms_Use.cfm Gas - Liquid Flow L/d = 1 L/d = 4 Gas L/d = 6 Liquid L/d = 10 L Fig. 1 Gas-liquid plug flow for different liquid slug lengths 2 Literature Review One of the earliest studies on laminar plug flow heat transfer is the study of Prothero and Burton 关3兴. In a one of a series of studies, they compared the heat transfer rate of single phase Graetz flow with that of a segmented gas-liquid stream. While Prothero and Burton 关3兴 were able to show enhancement over the single phase flow, they did not assess the effect of slug length. Rather, Prothero and Burton 关3兴 only considered the effect of void fraction in a limited sense. Their data will be presented in this study in a general plot in a later section but cannot be rereduced according to the approach suggested in this paper due to the lack of information on actual liquid plug lengths. Oliver and Wright 关5兴 conducted a series of measurements to investigate the effect of plug flow on heat transfer and friction in laminar flow. They surmised that the internal circulation would increase the heat transfer coefficient significantly and therefore, one would not be able to use the Graetz–Leveque theory. They attributed the increase in heat transfer coefficient to both the effects of internal circulation and increased liquid velocity that results at constant mass flow rates due to the void fraction. They concluded that the effect due to void fraction is independent of plug length but that circulation effects would be strongest for shorter plugs. They reserved the assessment of plug length for a later study since the apparatus they used to collect data could not control liquid plug lengths very well. As part of their study, Oliver and Wright 关5兴 developed simple correlations based on their experimental data and modification of the Graetz–Leveque model. Hughmark 关9兴 proposed a simple correlation using a modified Graetz–Leveque theory. However, his modifications were based on the experimental observations of Oliver and Wright 关5兴 and contained no new insights. Further, no rational basis was given for the proposed modification. The proposed model was reported as 冉 冊冉 冊 hTPD冑␣L ṁC p = 1.75 k ␣LkL 1/3 w 0.14 共1兲 Oliver and Young-Hoon 关6,7兴 developed an experimental facility to produce liquid plugs of constant length using gas as a segmenting medium. This study was motivated by the earlier study of Oliver and Wright 关5兴, which observed increased enhancement for Newtonian and non-Newtonian flows. Oliver and Young-Hoon 关6,7兴 conducted similar experiments as Oliver and Wright 关5兴, except that plug length and liquid fraction were carefully controlled. They obtained data for a segmented fluid stream of constant liquid mass flow rate that contained liquid plugs of uniform length and distribution. They reported data for two different liquid flow rates and for plugs varying in length from 1 in. to 20 in. in a 1/4 in. 共2.54 cm to 50.8 cm in a 6.35 mm兲 diameter tube. They could also control the rate of gas flow while maintaining the plug size to study the effect of gas stream velocity and hence, plug velocity. Heat transfer data were reported as a Nusselt number for the liquid phase versus a combined or two phase flow Graetz 041902-2 / Vol. 133, APRIL 2011 number. This was the first reported study to assess the effect of liquid plug length and liquid fraction on heat transfer. Horvath et al. 关4兴 obtained mass transfer data for liquid plugs of varying length for four Reynolds numbers using gas as a segmenting medium. They reported their data as a Nusselt number for the liquid plug phase only versus plug length at various Reynolds numbers for a stream having a constant liquid fraction of 0.5. The effect of plug velocity was studied by varying the two phase flow Reynolds number. Horvath et al. 关4兴 also examined the effect of dimensionless tube length for very short plugs, but these data cannot be used since the liquid fraction varies from point to point and is not reported. However, they showed that dimensionless tube length 共L / D兲 has a small effect on the overall heat transfer rate. We will delve into this issue in a later section. Vrentas et al. 关8兴 used solid steel spheres as a segmenting medium in a stream of silicone oil. They reported liquid phase Nusselt data as a function of the stream Peclet number for three plug lengths. They also considered two different Prandtl numbers. The primary distinguishing feature of this work is that the liquid plug ends cannot be assumed to be approximately adiabatic as in a gas-liquid flow as the authors report that the steel spheres heat up to the wall temperature and thus provide another heat transfer path. This issue becomes more pronounced for shorter plugs. However, we will make use of some of the data reported by Vrentas et al. 关8兴 for comparative purposes to illustrate the general scaling property. More recent studies using a numerical solution were undertaken by Lakehal et al. 关10兴 and Narayanan and Lakehal 关11兴. They re-examined the potential of nonboiling two phase plug flows as a means of heat transfer enhancement and proposed a simple model that, while modestly predicting their data, does not adequately address all the issues of plug length outlined above. Further, they combined the simple laminar fully developed flow Nusselt number with a turbulent flow Nusselt behavior despite the liquid flow Reynolds numbers falling in the laminar regime, 4/5 0.4 NuD ⬇ 3.67 + 0.022ReD Pr 共2兲 where ReD = UGD / is based on the gas phase velocity. Finally, Young and Mohensi 关12兴, Mohseni and Baird 关13兴, and Baird and Mohseni 关14兴 obtained numerical results for plug flows in a plane channel. They examined the heat transfer characteristics for a single droplet translating in a confined channel. They have coined the term digitized heat transfer to describe a discrete flow of droplets or plugs. The results reported 关12–14兴 are primarily concerned with low Peclet number flows using liquid metals as a proposed coolant. The reported behavior in Refs. 关12–14兴 is also the characteristic of the experimental data of the present authors 关15兴. Thus, while the initial interest in Refs. 关12–14兴 was heat transfer from microfluidic drops, all of the analysis that is presented is also applicable for laminar segmented flows in tubes and finite channels. Transactions of the ASME Downloaded 16 Mar 2011 to 134.153.184.170. Redistribution subject to ASME license or copyright; see http://www.asme.org/terms/Terms_Use.cfm Table 1 Summary of experimental and numerical data for tubes Parameter Ls / D L/D D 共mm兲 ReD Pr PeD Ls+ Ls쐓 L쐓 ␣L N Type Wall Oliver and Young-Hoon 关6兴 Horvath et al. 关4兴 Vrentas et al. 关8兴 Narayanan and Lakehal 关11兴 Walsh et al. 关15兴 1.2–74 144 6.35 977–1362 10 9770–13,620 0.00087–0.069 0.000077–0.0061 0.011–0.015 0.61–0.85 1–100 Gas-liquid Isothermal 1.6–20 260 2.32 30–220 1700 51,000–374,000 0.0042–0.73 0.0000025–0.00043 0.00069–0.0051 0.5 6–80 Gas-liquid Isothermal 10.5–61 128 9.5 0.7–15.8 1000, 10,000 4210–17,800 3.85–31.2 0.00083–0.0093 0.0073–0.030 0.913–0.984 2–12 Solid-liquid Isothermal 1.92–6.17 40 1 1396–2135 5.5 7678–11,742 0.0014–0.0029 0.00025–0.00052 0.0034–0.0052 0.520–0.795 2–10 Gas-liquid Isothermal 0.67–28.9 50 1.5 70–565 5.5 388–3106 0.0012–0.17 0.00022–0.031 0.016–0.13 0.11–0.8 1–37 Gas-liquid Isoflux Additional studies in the literature, such as Refs. 关16–18兴, also considered two phase plug flows; however, only the references discussed above have considered plug length and/or plug circulation at some level of detail. Due to the manner in which each of these studies presents Nusselt data, a direct comparison with single phase flow theory was not appropriately undertaken. These data will be re-examined and replotted using more appropriate definitions for the Nusselt number and dimensionless plug length, which coincide with the physics of a Graetz flow. The details of each data set are summarized in Table 1. These represent data for a circular tube. With the exception of Narayanan and Lakehal 关11兴, all data are experimental. Additional new data obtained by the authors will also be considered 关15兴. These data are obtained for the isoflux condition, but for this study, they have been presented as equivalent isothermal data using the mean wall temperature. In general, this is a reasonable approach as integration of the Graetz–Leveque equation for isoflux conditions yields an expression that is within 7% of the result for an isothermal tube wall. 3 Graetz Flow Problems We begin with a quick review of the Graetz flow theory and some useful alternatives for representing dimensionless heat transfer rates. As with external forced convection, a heat transfer coefficient is typically defined. Unlike external flows, where the stream temperature remains constant, i.e., T⬁, the temperature difference between the wall and the moving stream does not remain constant over the length of a duct or a channel, even in the case of constant wall temperature. In a duct or channel flow, we may define this wall to stream temperature difference in a number of different ways. These include • • • wall to bulk mean, Tw − Tm wall to inlet, Tw − Ti mean wall to inlet, T̄w − Ti The correct choice should be based on the application. For example, in single fluid problems such as heat sinks, the best and easiest approach is to use the wall to inlet temperature difference, Tw − Ti. However, in two fluid problems such as heat exchangers, the better choice is most often the wall to bulk temperature difference. The most frequently used form for defining the local heat transfer coefficient in an internal flow for constant wall temperature has traditionally been in terms of the bulk temperature, Tm = Tm共z兲, where Journal of Heat Transfer 冕冕 冕冕 c puTdA Tm = 共3兲 c pudA The local heat flux, qz, is often related to a local heat transfer coefficient, hz, by means of some defined characteristic temperature difference in the local flow, qz = hz共Tw − Tm兲 共4兲 where Tw − Tm is the local wall to bulk temperature difference. In a duct where the prescribed wall temperature remains constant, the heat flux varies due to changes in the bulk temperature. In a duct where the prescribed wall flux remains constant, the wall temperature varies. In these applications, the above equation is written as qw = hz共Tw,z − Tm兲 共5兲 and is utilized for determining the local wall temperature. Care must be taken when considering this issue, as either the wall may be maintained at a constant temperature or the wall heat flux may be maintained at a constant value but not both at the same time. In a real application, the true boundary condition may lie somewhere in between. Aggregate analysis using a mean wall temperature in flux specified problems and a mean flux in temperature specified problems often yields results within a few percent of each other. We may define a dimensionless local or mean heat transfer coefficient or Nusselt number for the two special cases of constant wall temperature and constant wall heat flux. These will be treated separately. Traditionally, the heat transfer rate is nondimensionalized using a Nusselt number defined as NuD = qD hD = k共Tw − Tm兲 k 共6兲 For the purposes of this study, we are primarily interested in dimensionless heat transfer rates using the wall to inlet temperature difference. Expressions differ slightly based on the thermal boundary condition prescribed. These are addressed below. 3.1 Constant Wall Temperature. If the duct wall is maintained at a uniform constant temperature Tw, then we define NuD = q zD k共Tw − Tm兲 共7兲 which is based on the wall to bulk mean fluid temperature. Alternatively, we could also define APRIL 2011, Vol. 133 / 041902-3 Downloaded 16 Mar 2011 to 134.153.184.170. Redistribution subject to ASME license or copyright; see http://www.asme.org/terms/Terms_Use.cfm NuD = q zD k共Tw − Ti兲 This definition proves useful in the boundary layer region for developing asymptotic solutions where the bulk temperature scales to the inlet fluid temperature, i.e., Tm ⬃ Ti. If a mean Nusselt number is desired, then we must integrate along the duct length NuD = 1 L쐓 冕 L쐓 NuDdz쐓 = 0 1 ⌬Tw = 쐓 L 共8兲 q̄D k⌬Tln 共9兲 However, in the case of a Nusselt number defined on the basis of the wall to inlet temperature difference, such as in the case of single fluid systems, i.e., heat sinks, it is more convenient to designate the dimensionless mean wall flux simply as: q̄D q쐓 = k共Tw − Ti兲 共10兲 NuD = q wD k共Tw,z − Tm兲 共11兲 0 q쐓 = 4 共12兲 in the thermal boundary layer region, where the bulk temperatures scales according to Tm ⬃ Ti. It is clear that if a uniform constant heat flux is specified, then the local Nusselt number is utilized for the purpose of predicting the wall to bulk fluid temperature rise or the wall temperature distribution once Tm is known. In other words, Tw,z = Tm + q wD kNuD 共13兲 In problems where the wall flux is prescribed, the concept of the heat transfer coefficient is limited. Thus, given an expression for the relationship of Nu as a function of dimensionless duct position zⴱ = z / DPeD, one can easily obtain the local wall or wall to bulk temperature difference. In this regard, in single fluid heat exchange systems, where the wall temperature is the parameter of interest, it is more appropriate to consider a dimensionless local wall temperature ⌬Tw쐓 = 共Tw,z − Ti兲k 1 = Nu q wD 共14兲 since the principal solution variable of interest will be the temperature field, Tw,z. Frequently, sources of Nu data and models report a mean Nusselt for the constant flux wall condition. In these cases, the mean heat transfer coefficient is utilized to find the mean wall to bulk temperature difference. This is only useful in the boundary layer or thermal entrance region where the wall to bulk temperature difference varies since in a fully developed flow, Tw,z − Tm is constant. If one desires the mean wall temperature or mean wall to bulk temperature difference, then we must obtain the integral relationship 041902-4 / Vol. 133, APRIL 2011 0 dz쐓 NuD 共15兲 q wD 共16兲 k⌬Tw Heat Transfer Characteristics Given the special scaling characteristics of the boundary layer and fully developed regions, it is convenient to examine several asymptotic formulations that can be used in a simple modeling approach. These include • fully developed flows • plug flow limit 共Pr→ 0兲 • Poiseuille flow limit 共Pr→ ⬁兲 Using the asymptotic characteristics of slug and Poiseuille flows for the constant wall boundary condition 关19,20兴 and the Churchill–Usagi asymptotic correlation method 关21,22兴, the authors have developed the following expressions for thermally developing Graetz flows. In the case of a slug flow, i.e., uniform velocity profile, one obtains for Nu and q쐓 the following: Nu = q wD k共Tw,z − Ti兲 冕 L쐓 These formulations involving Eqs. 共10兲 and 共16兲 will prove much more useful in the analysis of single fluid systems since the parameter of interest is defined explicitly in the nondimensional formulation. or, alternatively, as NuD = q wD 쐓 q wD dz = 쐓 kNuD kL Using the above result, we may define a dimensionless heat transfer rate similar to Eq. 共10兲 as in order to avoid confusion with the traditional definition of the Nusselt number. Since, in these applications, it is the total heat transfer rate related to the wall temperature and duct geometry that is of interest, not the actual heat transfer coefficient. 3.2 Constant Wall Flux. In other applications where electric resistance heating is used and/or we have a low conductivity duct wall, it may be more realistic to assume a constant heat flux boundary condition. If we maintain a constant flux at the wall, qw, then we may define a Nusselt number as 冕 L쐓 and q쐓 = 冋冉 冑 冊 1.128 L 2 + 5.782 쐓 册 1/2 冋冉 冑 冊 冉 冊 册 1.128 L −2 + 쐓 1 4L쐓 共17兲 −2 −1/2 共18兲 In the case of a Poiseuille flow, one obtains for Nu and q쐓 the following: Nu = and q쐓 = 冋冉 冊 1.614 L쐓1/3 5 + 3.655 册 1/5 冋冉 冊 冉 冊 册 1.614 L쐓1/3 −3/2 + 1 4L쐓 共19兲 −3/2 −2/3 共20兲 In all cases, the dimensionless thermal duct length is defined as L쐓 = L/D kL = PeD C pUD2 共21兲 The above expressions are used for comparing the available published data that have been used to assess plug length. They represent the theoretical solutions for the Graetz–Nusselt class of duct problems. The short duct asymptote, i.e., the first term in each of the latter two expressions, is also known as the Graetz–Leveque asymptote. The above equations are used in Sec. 5 to compare the experimental and numerical data of Table 1, assuming that the characteristic contact length 共or plug length兲 is used to define L쐓, actual local mean plug velocity U considering ␣L when required, and actual thermal contact area DL␣L, are used to define the dimensionless heat transfer rate. 5 Enhancement Mechanisms The hydrodynamics and heat transfer characteristics of plug flows varies depending on the type of segmenting medium, i.e., gas, liquid, or solid, and the surface characteristics. The principal Transactions of the ASME Downloaded 16 Mar 2011 to 134.153.184.170. Redistribution subject to ASME license or copyright; see http://www.asme.org/terms/Terms_Use.cfm 1.2 1 (a) 0.8 Q* Flow L 0.6 0.4 0.2 Segmented Slug / Continuous Slug Segmented Poiseuille / Continuous Poiseuille 0 -4 10 (b) 10 -3 10 -2 Flow 10 L* -1 10 0 10 1 Fig. 4 Q쐓 for segmented slug and Poiseuille Graetz flows having the same ṁ and no secondary flow mechanism L Fig. 2 Internal liquid plug circulation: „a… hydrophobic surface and „b… hydrophyllic surface mechanism for thermal enhancement is widely accepted to be fluid circulation, which is a result of interfacial effects, see Fig. 2. It has also been suggested that higher local fluid velocity for the same liquid feed rate in a gas-liquid flow also contributes to a higher heat transfer coefficient 关5兴. It can easily be shown that in a laminar Graetz flow, this increase in heat transfer coefficient is more than offset by the reduction in contact area and overall no gains in heat transfer result. In the absence of a secondary mechanism, i.e., interfacial effects, a fluid stream ideally would merely be divided into N segments such that a boundary layer is formed within each isolated segment and the stream would have a liquid fraction ␣L = 1. Regardless of whether the flow is Poiseuille or slug, the thermal boundary layer characteristics would in effect remain the same, as shown in Figs. 3共a兲 and 3共b兲. Since each segment would initiate a boundary layer on entering the tube, and as each segment translates downstream, its boundary layer grows in such a manner that the ensemble has the same boundary layer profile as a continuous stream. Thus, with no secondary mechanism 共interfacial effect兲 to change the local velocity profile, segmentation alone will not result in higher heat transfer coefficients. Next, if one assumes an ideal model whereby voids are created, as shown in Fig. 3共c兲, then the heat transfer characteristic will still be based on the actual tube length, not the segment or plug length, but with a reduced contact area. Further, if the stream has a liquid fraction less than one for the same mass flow rate, a reduced heat transfer rate would be observed due to a reduced liquid contact area despite a higher average heat transfer coefficient. In this case, the Nusselt number would merely rescale based on introducing the void fraction effects on surface area and mass flow. Further, it can be shown that the increase in local velocity at constant mass flow has no effect on enhancing the overall heat transfer rate, as the reduction in surface area outweighs an increase in heat transfer coefficient. We begin with the following simple models for ideal thermally developing plug flow, Eq. 共18兲, and ideal thermally developing (a) U (b) U (c) 2U Fig. 3 Ideal plug flow heat transfer Journal of Heat Transfer Poiseuille flow, Eq. 共20兲, in a tube with a constant wall temperature condition, i.e., Graetz flows, based on the inlet temperature difference Tw − Ti. The wall to inlet temperature difference forms are utilized since the wall to mean temperature difference approach would yield different values of the log mean temperature difference 共LMTD兲, and hence, direct comparison could not be made for a fixed temperature difference. We can define Q for each case while considering the liquid fraction ␣L for a stream having the same mass flow rate ṁ, i.e., L 쐓 → ␣ LL 쐓 共22兲 since the stream velocity becomes U → U / ␣L. Thus, it can easily be seen that increasing U for the same mass flow rate with the introduction of gas voids leads to a smaller effective L쐓 and hence a larger effective h. But one must also consider the reduced liquid contact area, i.e., Q s = ␣ LQ c共 ␣ LL 쐓兲 共23兲 To make a direct comparison with the continuous Graetz flow, we will also define a dimensionless heat transfer ratio Q쐓 = Qs / Qc, where Qs denotes the segmented flow heat transfer rate and Qc denotes the continuous flow heat transfer rate. This leads to the following expression for segmented slug flow relative to continuous slug flow denoted as 共s-s兲: ␣L 쐓 = Qs-s 冋冉 冑 冊 冉 冊 册 冋冉 冑 冊 冉 冊 册 1.128 ␣ LL 쐓 1.128 L쐓 and ␣L Q쐓p-p = −2 + 1 4 ␣ LL 쐓 + 1 4L쐓 −2 −2 −1/2 −2 −1/2 冋冉 冊 冉 冊 册 冋冉 冊 冉 冊 册 1.614 −3/2 1 + 共␣LL쐓兲1/3 4 ␣ LL 쐓 1.614 −3/2 1 −3/2 + 쐓1/3 L 4L쐓 共24兲 −3/2 −2/3 −2/3 共25兲 for segmented Poiseuille flow relative to continuous Poiseuille flow denoted as 共p-p兲. The results of Eqs. 共24兲 and 共25兲 are plotted in Fig. 4. It is clear that for a stream of constant mass flow rate, the effect of segmentation alone, i.e., introduction of voids with no interfacial effects assumed, will not enhance the heat transfer rate, as suggested by Oliver and Wright 关5兴. In fact, segmentation creates a large deficit in heat transfer rate that must be overcome by the interfacial circulation effect. Next, if we consider that the effect of a change in local velocity profile is a result of segmentation, i.e., the flow becoming more uniform or less parabolic, then a similar assessment as Eqs. 共24兲 and 共25兲 yields APRIL 2011, Vol. 133 / 041902-5 Downloaded 16 Mar 2011 to 134.153.184.170. Redistribution subject to ASME license or copyright; see http://www.asme.org/terms/Terms_Use.cfm 4 can therefore be manipulated through plug length and tube length. Thus, given a tube with a characteristic thermal length L쐓 for a continuous flow stream defined as Segmented Slug / Continuous Poiseuille 3 L쐓 = Q* 2 1 Ls쐓 = 10 共27兲 we will now define a new dimensionless thermal length for the segmented flow as 0 -5 10 L/D PeD -4 10 -3 10 -2 10 L* -1 10 0 10 1 PeD = 冋冉 冑 冊 冉 冊 册 冋冉 冊 冉 冊 册 쐓 Qs-p = −2 1.128 ␣ LL 1.614 L쐓1/3 쐓 + 1 4 ␣ LL 쐓 + 1 4L쐓 −3/2 共26兲 assuming a segmented slug flow relative to a continuous Poiseuille flow, denoted as 共s-p兲. In this case, one obtains the results in Fig. 5. It is clear that segmentation can lead to enhanced heat transfer over the same continuous flow stream if and only if a change in local velocity profile can be induced through segmentation, i.e., the interfacial effect. The change in local velocity profile has been demonstrated in a recent paper by King et al. 关23兴, which shows that segmentation produces velocity profiles that lie between Poiseuille and slug flows, which also depend strongly on plug length. In an actual segmented fluid stream, interfacial effects give rise to internal circulations within the liquid plugs, as shown in Fig. 2. The plug configuration shown in Fig. 2共b兲 is typical of those produced in gas-liquid interfaces. These circulations increase the radial transport of heat and in effect give rise to a renewal in thermal boundary layer by continuously replenishing the heated fluid near the wall with cooler fluid from the core. In these cases, the heat transfer rate can thus be controlled by plug length, as circulation effects become less pronounced for longer slugs. Therefore, the only way to make the curves in Fig. 4 give rise to Q쐓 ⬎ 1 is to effectively reduce the L쐓 of the segmented flow. This is analogous to slotting of surfaces in compact heat exchangers utilizing fins. This can only be achieved through a secondary mechanism such as circulation, which reduces the characteristic thermal length of the system since each plug is now, in essence, decoupled from the behavior shown in Fig. 3共c兲, since the boundary layer characteristics no longer depend on axial position of the plug but rather on the length of the plug. The induced plug circulations give rise to an oscillatory behavior in local and mean Nusselt numbers, as reported in Refs. 关12–15兴. These oscillations in Nusselt number result from the local circulation effect and begin downstream at one plug length from the inlet. After three to five oscillations, the effect is essentially dampened out and the flow reaches a new but higher fully developed flow Nusselt number. Provided that a heated tube is of sufficient length that several circulations occur over the flow length, the thermal characteristics are such that a higher but constant Nusselt number will be observed. In the work of Horvath et al. 关4兴, the authors observed a slight dependency on dimensionless duct length L / D for this reason, as their experiments typically had many plugs in the flow stream at any instant 共see Table 1兲. The thermal boundary layer characteristics in a segmented flow 041902-6 / Vol. 133, APRIL 2011 共29兲 L ⬃ ␣ L N 共30兲 where N is the plug count in the tube and is the pitch of the plug train. Thus, we can obtain −2 −1/2 −3/2 −2/3 4ṁ D␣ But the plug length Ls can be related to the original tube length by means of Ls ⬃ ␣L ␣L 共28兲 where PeD is defined using the mass flow rate of the liquid stream, 쐓 Fig. 5 Q for segmented slug versus continuous Poiseuille Graetz flows having the same ṁ and no secondary flow mechanism Ls/D PeD/␣L Ls쐓 = ␣L2 쐓 L N 共31兲 Therefore, considering both the effect of liquid fraction ␣L and plug count N, a reduction in the effective dimensionless thermal length is achieved by means of the factor ␣L2 / N. Since ␣L ⬍ 1 and N ⬎ 1 for a segmented flow, considerable increases in heat transfer coefficient can be obtained. If we consider a continuous flow having a dimensionless thermal length of L쐓 ⬃ 0.1 close to the optimal length for a single phase flow and develop a plug train having a liquid fraction of 0.5 and only one plug, we obtain a theoretical enhancement ratio of 1.55 for the same feed rate. This simple example clearly illustrates the promise of gas-liquid segmented flow. Further, even with the mean liquid velocity two times higher for the same mass flow rate, the pressure drop in laminar flow is still quite reasonable 关1,22兴. In general, when Ls / D ⬎ 15, the pressure drop is not appreciably changed over the single phase flow stream as most of the pressure drop is due to liquid shear at the tube wall. 6 Data Scaling and Analysis Since heat transfer occurs primarily to the liquid stream and not to the segmenting gas medium, both the Nusselt number and dimensionless plug length should use the thermophysical properties of the liquid. Further, only the wetted heat transfer surface should be used in rendering the Nusselt data and not the total tube area. The independent parameter 共dimensionless thermal length兲 is defined on the basis of the plug length and plug characteristics and not based on the tube length as done in previous studies. Using the present convention, this yields the true heat transfer coefficient for the liquid phase and also allows for a proper comparison with single phase Graetz theory. Only the study of Vrentas et al. 关8兴 came close to this reduction scheme since the authors had accounted for all heat transfer to the liquid and defined the Peclet number using the actual liquid velocity for the same mass flow rate as used in their single phase experiments. However, the authors used the dimensionless plug length Ls / D as a characterizing parameter to generate a family of curves but did not use it directly as a Graetz flow parameter. The data of the four studies summarized in Table 1 are now re-examined considering plug length and liquid fraction as the controlling variables. In this present work, we have chosen to redefine the dependent and independent variables so that all the Transactions of the ASME Downloaded 16 Mar 2011 to 134.153.184.170. Redistribution subject to ASME license or copyright; see http://www.asme.org/terms/Terms_Use.cfm 102 1 3 10 2 10 1 10 0 Oliver and Young-Hoon (1968) - A Oliver and Young-Hoon (1968) - B Oliver and Young-Hoon (1968) - C Oliver and Young-Hoon (1968) - D Graetz-Poiseuille Flow Theory q* q* 10 10 10 10 Oliver and Young-Hoon (1968) - A Oliver and Young-Hoon (1968) - B Oliver and Young-Hoon (1968) - C Oliver and Young-Hoon (1968) - D Horvath et al. (1973) Vrentas et al. (1978) Lakehal and Narayanan (2008) Prothero and Burton (1961) Graetz-Poiseuille Flow Theory Graetz-Slug Flow Theory 0 -1 10 -3 10 -2 L* 10 10 -4 L*s 10 -3 10 -2 -1 Fig. 7 Data of Oliver and Young-Hoon †6,7‡ replotted considering plug length and liquid fraction Fig. 6 All data plotted using nondimensional scaling consistent with total tube length when reducing data Q/共␣LA兲 h̄D = k⌬Tln k NuD = 共32兲 based on actual wetted surface area and q쐓 = Q/共␣LA兲 1 关1 − exp共− 4NuDLs쐓兲兴 = k共Tw − Ti兲 4Ls쐓 共33兲 which may easily be related to the mean Nusselt number and then Ls쐓. The dimensionless thermal length Ls쐓 is now based on the local liquid plug velocity and plug length, i.e., Ls쐓 = Ls/D Ls/D = PeD UD/␣ 共34兲 or, if written in terms of the liquid stream mass flow rate, Ls쐓 = ␣ LL sk 4ṁC p 共35兲 Equations 共32兲 and 共35兲 reduce to their single phase flow counterparts when ␣L → 1. Thus, the effects of plug length and liquid fraction can be properly addressed from the point of view of the actual heat transfer coefficient, or put another way, the actual heat transfer rate. This is quite important since in all the studies given in Table 1, the Nusselt number is reported based on either the total surface area or the wetted surface area, while the dimensionless thermal length is always based on the true duct length. Both of these issues have lead the published data showing no correlation with single phase Graetz flows. To illustrate this issue, all of the data from the studies summarized in Table 1 are plotted in Fig. 6. In all cases, one can see that the effect of reducing slug length is an increase in the nominal Nusselt number based on total tube area when plotted against the dimensionless thermal length based on total tube length. Figure 6 illustrates directly the level of enhancement that can be achieved with a segmented stream over a continuous stream. However, in this form, no means of prediction can be achieved. If one considers the carefully obtained data of Horvath et al. 关4兴, it can be seen that as plug length decreases, the nominal Nusselt number increases and in fact surpasses the Graetz slug flow line. In the study of Oliver and Young-Hoon 关6,7兴, the authors based the Nusselt number on the total surface area of the tube and define a two phase Graetz number using a velocity equal to the sum of the liquid and gas velocities. Data were presented showing the effect of dimensionless local plug velocity 共Graetz number兲 and plug length on the Nusselt number. These data sets are denoted as A and B in Fig. 6. Data were also presented showing Nusselt Journal of Heat Transfer 103 Horvath et al. (1973) Graetz-Poiseuille Flow Theory 102 q* results may be easily compared with the simpler single phase Graetz flow theory. Data are re-analyzed considering the following definitions: number variation with plug length and liquid fraction for a constant mass flow rate. These data sets are denoted as C and D in Fig. 6. Both sets of data have been reduced using the information in the original paper along with the observations of Hughmark 关9兴 on liquid holdup calculations for laminar flows when the component gas and liquid flow rates are known. These data are presented in Fig. 7 along with the simple Graetz flow theory. One can see that a redistribution of the experimental data has occurred, with the data now uniformly spread along the Graetz flow theory. The data reported in Refs. 关6,7兴 for Nu versus Gz and Ls show much less scatter. In the study of Horvath et al. 关4兴 and Vrentas et al. 关8兴, the authors based the Nusselt number on the wetted surface area, DL␣L, but Horvath et al. 关4兴 defined the Reynolds number using the sum of the phase velocities as was done by Oliver and YoungHoon 关6,7兴, whereas Vrentas et al. 关8兴 defined the Reynolds number using the local liquid plug velocity. In both studies, the Nusselt data are plotted versus the Reynolds number 关3兴 or the Peclet number 关8兴 for various dimensionless plug lengths Ls / D. In this form, the data clearly show increased Nusselt values with decreasing plug length. The data of these two studies have been reanalyzed and plotted versus Ls쐓. Figure 8 presents the data of Horvath et al. 关4兴 while the data of Vrentas et al. 关8兴 are given in Fig. 9. The data of Horvath et al. 关4兴 clearly demonstrate the scaling of heat transfer data with dimensionless plug length. The data of Vrentas et al. 关8兴 are somewhat higher for the larger Ls / D ratios. This can be explained by the fact that in their experiments for these plug lengths, typically, there were between two and four liquid plugs. Additional data of Horvath et al. 关4兴 show that a modest entrance effect occurs as tube length decreases for a given flow. In other words, as tube length decreases, plug count N also decreases. The available data and our own experimental observations 关15兴 indicate that if fewer than five plugs exist in the plug 10 1 0 10 -6 10 10-5 L*s 10-4 10- Fig. 8 Data of Horvath et al. †4‡ replotted considering plug length and liquid fraction APRIL 2011, Vol. 133 / 041902-7 Downloaded 16 Mar 2011 to 134.153.184.170. Redistribution subject to ASME license or copyright; see http://www.asme.org/terms/Terms_Use.cfm 103 103 Vrentas et al. (1978) - L/D = 128 Vrentas et al. (1978) - Ls/D = 10.5 Vrentas et al. (1978) - Ls/D = 33.5 Vrentas et al. (1978) - Ls/D = 61 Lakehal and Narayanan (2008) Graetz-Poiseuille Flow Theory 102 q* q* 102 10 Oliver and Young-Hoon (1968) - A Oliver and Young-Hoon (1968) - B Oliver and Young-Hoon (1968) - C Oliver and Young-Hoon (1968) - D Horvath et al. (1973) Vrentas et al. (1978) Lakehal and Narayanan (2008) Walsh et al. (2009) Graetz-Poiseuille Flow Theory 1 0 10 -4 10 10 10-3 L*s 10-2 0 10 -6 10 10-1 Fig. 9 Data of Vrentas et al. †8‡ and Narayanan and Lakehal †11‡ replotted considering plug length and liquid fraction 10-5 10-4 10-3 L*s 10-2 10- Fig. 11 All data replotted considering plug length and liquid fraction in the data reduction 7 train, higher heat transfer rates are observed over the case of plug trains with many plugs in excess of 5. This would indicate that for the isothermal boundary condition, a fully developed recirculating heat transfer coefficient is obtained. It is this recirculating flow characteristic that leads to the Ls / D scaling that is observed in the present data sets. Finally, Narayanan and Lakehal 关11兴 undertook a numerical study of segmented flow in a minitube and define the Nusselt number using the total surface area and the Reynolds number using the gas velocity and liquid properties. The data have been re-analyzed according to Eqs. 共32兲 and 共35兲 and have also been plotted in Fig. 9 with the data of Vrentas et al. 关8兴. These comparisons are only for a qualitative scaling purpose. Recent data obtained by the authors on electrically heated tubes are presented in Fig. 10. The data that are obtained for an isoflux boundary condition have been reduced according to Eq. 共16兲 to make comparisons with the mean isothermal wall theory developed earlier. These data represent the fully developed flow or limiting Nusselt numbers. Two types of data are presented. Those with plug counts less than 3, and those with plug counts greater than 7. In the latter, the integrated mean wall temperature is higher than in the former case, and the data for q쐓 appear lower. All data are now plotted in Fig. 11 along with the single phase Graetz theory. Overall, the predictive ability of the single phase Graetz flow theory for a gas-liquid segmented flow appears sound, particularly when compared with Fig. 6 共i.e., before rescaling L쐓兲. The effect of plug length as a controlling variable is clearly being demonstrated. 1 Predictive Heat Transfer Model The proposed model is now summarized for a laminar gasliquid segmented flow. The dimensionless mean heat flux for an isothermal wall based on wetted contact area can be determined using q쐓 = 冋冉 冊 冉 冊 册 1.614 −3/2 1 + Ls쐓1/3 4Ls쐓 −3/2 −2/3 共36兲 where q쐓 = Q/共␣LDL兲D k共Tw − Ti兲 共37兲 ␣ LL sk 4ṁC p 共38兲 and Ls쐓 = Equation 共36兲 is applicable to segmented flow systems assuming that N ⲏ 5, i.e., typically more than five plugs in the heated tube at any given time. Further, given the nature of thermal entrance length problems, the axial residence time of the plug flow should provide for L쐓 ⱗ 0.1 since even a short liquid plug experiencing a higher heat transfer coefficient will become thermally saturated after this distance is achieved. In a laminar Taylor 共plug兲 flow, it has been well documented that the liquid fraction can be approximated very well using ␣L ⬇ Q̇l Q̇l + Q̇g 共39兲 or if there is significant liquid film around the gas voids, the Armand 关24兴 correlation ␣L ⬇ 0.83 103 Walsh (2009) - N < 3 Graetz-Poiseuille Flow Theory Walsh (2009) - N > 7 q* 1 0 10 -4 10 10-3 L*s 10-2 共40兲 10- Fig. 10 Data of Walsh et al. †15‡ replotted considering plug length and liquid fraction 041902-8 / Vol. 133, APRIL 2011 Q̇l + Q̇g may be used. Since it is anticipated that most applications will involve liquid cooled heat sinks, we limit ourselves to the dimensionless heat transfer rate based on the inlet temperature difference Tw − Ti. However, in a two fluid-type heat exchanger, Eqs. 共36兲 and 共37兲 can be replaced by Eq. 共19兲 with L쐓 replaced with Ls쐓 and Eq. 共32兲 in order to compute the heat transfer coefficient, h, based on the wall to bulk temperature difference. If pressure drop is also desired, the reader is directed to another recent work of the authors 关25兴. 102 10 Q̇l 8 Summary and Conclusions Nonboiling gas-liquid plug flow heat transfer was examined from the point of view of plug length and plug circulation. Since Transactions of the ASME Downloaded 16 Mar 2011 to 134.153.184.170. Redistribution subject to ASME license or copyright; see http://www.asme.org/terms/Terms_Use.cfm plug circulation is closely related to plug length, it was shown that the effect of plug length on boundary layer renewal is strong, and as such, predictive methods should utilize the actual plug length when applying classic Graetz flow theory. Using the limited available data from the literature and some new data of the authors, we have shown that better scaling of the dimensionless data is obtained when true wetted surface area and plug length are considered. It was shown that data redistribute themselves along the Graetz–Poiseuille curve with a considerable reduction in scatter and predictive error. Overall, root mean square 共rms兲 errors are reduced from 120% to 24% for all data sets. In the case of four of these carefully obtained data sets, the rms error is approximately 10–15%. Acknowledgment The authors acknowledge the financial support of the Natural Sciences and Engineering Research Council of Canada 共NSERC兲 and Enterprise Ireland 共EI兲. Nomenclature A Cp D Gz h k L Ls L쐓 Ls쐓 ṁ N NuD P PeD Pr q̄ q쐓 Q Q̇g Q̇l Q쐓 ReD T Ti Tm Tw ⌬T쐓 U z ⫽ ⫽ ⫽ ⫽ ⫽ ⫽ ⫽ ⫽ ⫽ ⫽ ⫽ ⫽ ⫽ ⫽ ⫽ ⫽ ⫽ ⫽ ⫽ ⫽ ⫽ ⫽ ⫽ ⫽ ⫽ ⫽ ⫽ ⫽ ⫽ ⫽ Greek Symbols ␣ ⫽ ␣L ⫽ ⑀ ⫽ ⫽ ⫽ ⫽ ⫽ flow area, m2 specific heat, J / kg K diameter of circular duct, m Graetz number 共⬅ṁC p / kL兲 heat transfer coefficient, W / m2 K thermal conductivity, W / m K length of tube, m length of liquid plug, m dimensionless length of tube 共⬅L / DPeD兲 dimensionless length of plug 共⬅Ls / DPeD兲 liquid mass flow rate, kg/s number of plugs in tube Nusselt number 共⬅hD / k兲 perimeter, m Peclet number 共⬅UD / ␣兲 Prandtl number 共⬅ / ␣兲 mean heat flux, W / m2 dimensionless wall heat flux heat transfer, W gas flow rate, m3 / s liquid flow rate, m3 / s thermal enhancement ratio Reynolds number 共⬅UD / 兲 temperature, K inlet temperature, K bulk temperature, K wall temperature, K dimensionless temperature average liquid velocity, m/s local axial coordinate, m thermal diffusivity, m2 / s liquid fraction 共⬅1 − ⑀兲 void fraction plug pitch, m dynamic viscosity, N s / m2 kinematic viscosity, m2 / s fluid density, kg/ m3 Superscripts 쐓 ⫽ dimensionless 共 · 兲 ⫽ mean value Journal of Heat Transfer Subscripts c D i m pois s slug w z ⫽ ⫽ ⫽ ⫽ ⫽ ⫽ ⫽ ⫽ ⫽ continuous based on diameter D inlet mixed mean Poiseuille flow segmented slug flow wall local 共axial兲 variation References 关1兴 Kreutzer, M. 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