Thermal Analysis of Hybrid Thermal Control System and Experimental Investigation of Flow Boiling in Micro-channel Heat Exchangers

Seunghyun Lee, Purdue University

Abstract

Future manned space endeavors will require a new class of vehicles, capable of conducting different types of missions and enduring varying gravitational and temperature environments. Thermal management will play a vital role in these new vehicles, and is complicated by the need to tackle both low and high heat sink temperatures. The present study assesses the feasibility of hybrid thermal control system by thermodynamic analysis and investigates the heat transfer mechanisms in two large micro-channel heat exchangers in vapor compression mode and two-phase mode. Unlike prior published two-phase micro-channel studies that concern mostly miniature heat sinks, this study addresses transport characteristics of a heat sink containing large length-to-diameter ratio, up to 609.6 to 1,micro-channels. In the thermodynamic analysis, four different operational modes are considered: single-phase, two-phase, basic heat pump and heat pump with liquid-side, suction-side heat exchanger. A thermodynamic trade study is conducted for six different working fluids to assess important performance parameters including mass flow rate of the working fluid, maximum pressure, radiator area, compressor/pump work, and coefficient of performance (COP). R134a is determined to be most suitable based on its ability to provide a balanced compromise between reducing flow rate and maintaining low system pressure, and a moderate coefficient of performance (COP); this fluid is also both nontoxic and nonflammable, and features zero ozone depletion potential (ODP) and low global warming potential (GWP). It is shown how specific mission stages dictate which mode of operation is most suitable, and this information is used to size the radiator for the H-TCS. The experimental flow boiling investigation consists of exploring the steady-state and the transient two-phase heat transfer characteristics of two large micro-channel heat exchangers that serve as evaporators in the vapor compression loop using R134a as refrigerant. Both heat exchangers feature parallel micro-channels with identical 1x1-mm2 cross-sections. The evaporators are connected in series, with the smaller 152.4-mm long heat exchanger situated upstream of the larger 609.6-mm long heat exchanger. In the steady-state characteristics part, it is shown low qualities are associated with slug flow and dominated by nucleate boiling, and high qualities with annular flow and convective boiling. Important transition points between the different heat transfer regimes are identified as (1) intermittent dryout, resulting from vapor blanket formation in liquid slugs and/or partial dryout in the liquid film surrounding elongated bubbles, (2) incipient dryout, resulting from dry patch formation in the annular film, and (3) complete dryout, following which the wall has to rely entirely on the mild cooling provided by droplets deposited from the vapor core. In the transient characteristics part, heat transfer measurement and high speed video are used to investigate variations of heat transfer coefficient with quality for different mass velocities and heat fluxes, as well as transient fluid flow and heat transfer behavior. An important transient phenomenon that influences both fluid flow and heat transfer is a liquid wave composed of remnants of liquid slugs from the slug flow regime. The liquid wave serves to replenish dry wall patches in the slug flow regime and to a lesser extent the annular regime. Unlike small heat sinks employed in the electronics industry, TCS heat sinks are characterized by large length-to-diameter ratio, for which limited information is presently available. The large length-to-diameter ratio of 609.6 is especially instrumental to capturing detailed axial variations of flow pattern and corresponding variations in local heat transfer coefficient. High-speed video analysis of the inlet plenum shows appreciable vapor backflow under certain operating conditions, which is also reflected in periodic oscillations in the measured pressure drop. In fact, the backflow frequency captured by video matches closely the frequency obtained from Fourier analysis of the pressure drop signal. It is shown the periodic oscillations and vapor backflow are responsible for initiating intermittent dryout and appreciable drop in local heat transfer coefficient in the downstream regions of the channels. A parametric study of oscillation frequency shows a dependence on four dimensionless parameters that account for amount of vapor generation, subcooling, and upstream liquid length, in addition to Weber number. A new correlation for oscillation frequency is constructed that captures the frequency variations relative to these individual parameters. (Abstract shortened by ProQuest.)

Degree

Ph.D.

Advisors

Mudawar, Purdue University.

Subject Area

Fluid mechanics|Aerospace engineering|Mechanical engineering

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