Search Results (17)

This review article highlights the critical impact of surface roughness in modifying the structure of two-phase flow within mini- and microchannels, particularly in processes such as boiling and condensation. Channel surface roughness enhances flow resistance, affects the distribution of vapor bubbles, and enhances heat transfer by providing additional nucleation sites. Several experiments have shown that while increased surface roughness enhances the efficiency of heat transfer, increased flow resistance may hurt system performance. This is so because too high a surface roughness negatively impacts flow resistance, a factor of importance in the optimization for a balance between heat transfer and flow resistance, especially in high-performance compact heat exchangers. Furthermore, the review identifies that higher-degree measurement and characterization techniques of the surface roughness are increasingly required, as traditional 2D parameters may not fully represent the actual physics of complex surface interactions in two-phase flow systems. Consequently, the article calls for further research that can examine the exact relationship between roughness, flow structure, and thermal performance with the aim of improving design strategies for future heat exchanger technologies. Full article

Researchers have attempted to improve heat transfer in mini/microchannel heat sinks by dispersing nano-encapsulated phase change (NPC) materials in base coolants. While NPC slurries have demonstrated improved heat transfer performance, their applications are limited by decreasing enhancement at increased flow rates. To address this challenge, the present study numerically investigates the effects of wavy channels on the performance of NPC slurries. Simulation results reveal that a wavy channel induces Dean vortices that intensify the mixing of the working fluid and enlarge the melting fractions of the NPC material, thus offering a significantly higher heat transfer efficiency than a straight channel. Moreover, heat transfer enhancement by NPC slurries varies with the imposed heat flux and flow rate. Interestingly, the maximum heat transfer enhancement obtained with the wavy channel not only exceeds the straight one, but also occurs at a higher heat flux and faster flow rate. This finding demonstrates the advantage of wavy channels in management of intensive heat fluxes with NPC slurries. The study also investigates wavy channels with varying amplitude and wavelength. Increasing the wave aspect ratio from 0.2 to 0.588 strengthens Dean vortices and consequently increases the Nusselt number, optimal heat flux, and overall thermal performance factor. Full article

With the growing demand for photovoltaic (PV) systems as a source of energy generation that produces no greenhouse gas emissions, effective strategies are needed to address the inherent inefficiencies of PV systems. These systems typically absorb only approximately 15% of solar energy and experience performance degradation due to temperature increases during operation. To address these issues, PV–thermal (PVT) technology, which combines PV with a thermal absorber to dissipate excess heat and convert it into additional thermal energy, is being rapidly developed. This review presents an overview of various PVT technologies designed to prevent overheating in operational systems and to enhance heat transfer from the solar cells to the absorber. The methods explored include innovative absorber designs that focus on increasing the heat transfer contact surface, using mini/microchannels for improved heat transfer contiguity, and substituting traditional metal materials with polymers to reduce construction costs while utilizing polymer flexibility. The review also discusses incorporating phase change materials for latent heat absorption and using nanofluids as coolant mediums, which offer higher thermal conductivity than pure water. This review highlights significant observations and challenges associated with absorber design, mini/microchannels, polymer materials, phase change materials, and nanofluids in terms of PV waste heat dissipation. It includes a summary of relevant numerical and experimental studies to facilitate comparisons of each development approach. Full article

Nowadays, the demand for obtaining high heat flux values in small volumes has increased with the development of technology. Condensing flow inside mini- and microchannels has been becoming a promising solution for refrigeration, HVAC, air-conditioning, heat pumps, heat pipes, and electronic cooling applications. In these applications, employing mini/microchannels in the condenser design results in the working fluid, generally refrigerant, undergoing a phase change inside the mini/microchannels. On the other hand, the reduction in the hydraulic diameter during condensation gives rise to different flow regimes and heat transfer mechanisms in the mini- and microchannels compared to the conventional channels. Therefore, the understanding of fluid flow and heat transfer characteristics during condensation of refrigerant inside mini- and microchannels has been gaining importance in terms of condenser design. This study presents a state-of-the-art review of condensation studies on refrigerants inside mini- and microchannels. The review includes experimental studies as well as correlation models, which are developed to predict condensation heat transfer coefficients and pressure drop. The refrigerant type, thermodynamical performance, and compatibility, as well as the environmental effects of refrigerant, play a decisive role in the design of refrigeration systems. Therefore, the environmental impacts of refrigerants and current regulations against them are also discussed in the present review. Full article

Recent advancements in computational fluid dynamics (CFD) have triggered research in the field of heat exchangers. Driven by the need to decrease the size of heat exchangers, many researchers have exploited the higher heat transfer achieved by replacing single-phase flow systems with boiling counterparts. The concept of using mini-channels to provide compact heat exchangers while maintaining heat transfer performance is relatively new. A minimal number of researchers have reported simulations of water-steam systems in mini-channels. This paper presents a numerical study of the heat transfer performance (HTP) of mini channels in a water-steam system using the volume of fluid (VOF) model coupled with the Lee phase change model on commercial CFD software ANSYS. The numerical model consisted of a $1 \mathrm{mm} \times 1.5 \mathrm{mm} \times 52 \mathrm{mm}$ channel with boundary conditions: top adiabatic; constant heat flux at the bottom surface; left/right periodic; mass flow inlet and pressure outlet. A mesh independence study was carried out for the proposed model, and simulations were validated against the experimental results of heat transfer versus vapor quality for a wide range of mass and heat fluxes. The VOF model best predicts experimental HTC at high mass fluxes, although the results at low mass fluxes were predicted with reasonable accuracy. Based on the agreement of numerical and numerical results, the VOF model turned out to be a promising candidate for designing compact micro/mini channel heat exchangers. Full article

Microelectromechanical systems (MEMS)-based filter with microchannels enables the removal of various microorganisms, including viruses and bacteria, from fluids. Membranes with porous channels can be used as filtration interfaces in MEMS hemofilters or mini-dialyzers. The main problems associated with the filtration process are optimization of membrane geometry and fouling. A nanoporous aluminum oxide membrane was fabricated using an optimized two-step anodization process. Computational strength modeling and analysis of the membrane with specified parameters were performed using the ANSYS structural module. A fuzzy simulation was performed for the numerical analysis of flux through the membrane. The membrane was then incorporated with the prototype for successive filtration. The fluid flux and permeation analysis of the filtration process have been studied. Scanning electron microscope (SEM) micrographs of membranes have been obtained before and after the filtration cycles. The SEM results indicate membrane fouling after multiple cycles, and thus the flux is affected. This type of fabricated membrane and setup are suitable for the separation and purification of various fluids. However, after several filtration cycles, the membrane was degraded. It requires a prolonged chemical cleaning. High-density water has been used for filtration purposes, so this MEMS-based filter can also be used as a mini-dialyzer and hemofilter in various applications for filtration. Such a demonstration also opens up a new strategy for maximizing filtration efficiency and reducing energy costs for the filtration process by using a layered membrane setup. Full article

Flat mini heat pipes (FMHPs) are often used in cooling systems for various power electronic components, as they rapidly dissipate high heat flux densities. The main objective of the present work is to experimentally investigate whether differences in the rate of vapor formation occur on an internal structure containing trapezoidal microchannels and porous sintered copper powder material. Several parameters, such as hydraulic diameter and fluid velocity through the material, as a function of the internal structure porosity, were determined by calculation for a steady state regime. Reynolds number was determined as a function of porosity, according to Darcy’s law, and the Nusselt number was calculated. Since the flow is Darcy-type through the porous medium inside the FMHP, the Darcy friction factor was calculated using five methods: Colebrook, Darcy–Weisbach, Swamee–Jain, Blasius, and Haaland. After experimental tests, it was found that when the porous and trapezoidal microchannel layers are wetted at the same time, the vaporization progresses at a faster rate in the porous material, and the duration of the process is shorter. This recommends the use of such an internal structure in FMHPs since the manufacturing technology is simpler, the materials are cheaper, and the heat flux transport capacity is higher. Full article

Flow boiling within conventional, mini and micro-scale channels is encountered in a wide range of engineering applications such as nuclear reactors, steam engines and cooling of electronic devices. Due to the high complexity and importance of the boiling process, several numerical and experimental investigations have been conducted for the better understanding of the underpinned physics and heat transfer characteristics. One of the most widely used numerical approaches that can analyse such phenomena is the Eulerian–Eulerian two-fluid method in conjunction with the RPI model. However, according to the current state-of-the-art methods this modelling approach heavily relies on empirical closure relationships derived for conventional channels, limiting its applicability to mini- and micro-scale channels. The present paper aims to give further insights into the applicability of this modelling approach for non-conventional channels. For this purpose, a numerical investigation utilising the Eulerian–Eulerian two-fluid model and the RPI wall heat flux partitioning model in OpenFOAM 8.0 is conducted. Initially the parameters comprising the empirical closure relationships used in the RPI sub-models are tuned against the DEBORA experiments on conventional channels, through an extensive sensitivity analysis. In the second part of the investigation, numerical simulations against flow boiling experiments within micro-channels are performed, utilising the previously optimised and validated model setup. Furthermore the importance of including a bubble coalescence and break-up sub-model to capture parameters such as the radial velocity profiles, is also illustrated. However, when the optimal model setup, in conventional tubes, is used against micro-channel experiments, the need to develop new correlations from data obtained from mini and micro-scale channel studies, not from experimental data on conventional channels, is revealed. Full article

An effective way to enhance the heat transfer in mini and micro electronic devices is to use different shapes of micro-channels containing vortex generators (VGs). This attracts researchers due to the reduced volume of the electronic micro-chips and increase in the heat generated from the devices. Another way to enhance the heat transfer is using nanofluids, which are considered to have great potential for heat transfer enhancement and are highly suited to application in practical heat transfer processes. Recently, several important studies have been carried out to understand and explain the causes of the enhancement or control of heat transfer using nanofluids. The main aim upon which the present work is based is to give a comprehensive review on the research progress on the heat transfer and fluid flow characteristics of nanofluids for both single- and two- phase models in different types of micro-channels. Both experimental and numerical studies have been reviewed for traditional and nanofluids in different types and shapes of micro-channels with vortex generators. It was found that the optimization of heat transfer enhancement should consider the pumping power reduction when evaluating the improvement of heat transfer. Full article

A general correlation for predicting the two-phase heat transfer coefficient (HTC) during condensation inside multi-port mini/micro-channels was presented. The model was obtained by correlating the two-phase multiplier, ${\phi }_{tp}$ with affecting parameters using the genetic programming (GP) method. An extensive database containing 3503 experimental data samples was gathered from 21 different sources, including a broad range of operating parameters. The newly obtained correlation fits the broad range of measured data analyzed with an average absolute relative deviation (AARD) of 16.87% and estimates 84.73% of analyzed data points with a relative error of less than 30%. Evaluation of previous correlations was also conducted using the same database. They showed the AARD values ranging from 36.94% to 191.19%. However, the GP model provides more accurate results, AARD lower than 17%, by considering the surface tension effects. Finally, the effect of various operating parameters on the HTC was studied using the proposed correlation. Full article

Stereolithographic printing (SL) is widely used to create mini/microfluidic devices; however, the formation of microchannels smaller than 500 μm with good inner surface quality is still challenging due to the printing resolution of current commercial printers and the z-overcure error and scalloping phenomena. In the current study, we used SL printing to create microchannels with the aim of achieving a high degree of dimensional precision and a high-quality microchannel inner surface. Extensive experiments were performed and our results revealed the following: (1) the SL printing of microchannels can be implemented in three steps including channel layer printing, an oxygen inhibition process, and roof layer printing; (2) printing thickness should be reduced to minimize the scalloping phenomenon, which significantly improves dimensional accuracy and the quality of inner microchannel surfaces; (3) the inclusion of an oxygen inhibition step is a critical and efficient approach to suppressing the z-overcure error in order to eliminate the formation of in-channel obstructions; (4) microchannels with an extremely high aspect ratio of 40:1 (4000 μm in height and 100 μm in width) can be successfully manufactured within one hour by following the three-step printing process. Full article

Droplet microfluidics is an extremely useful and powerful tool for industrial, environmental, and biotechnological applications, due to advantages such as the small volume of reagents required, ultrahigh-throughput, precise control, and independent manipulations of each droplet. For the generation of monodisperse water-in-oil droplets, usually T-junction and flow-focusing microfluidic devices connected to syringe pumps or pressure controllers are used. Here, we investigated droplet-generation regimes in a flow-focusing microfluidic device induced by the negative pressure in the outlet reservoir, generated by a low-cost mini diaphragm vacuum pump. During the study, we compared two ways of adjusting the negative pressure using a compact electro-pneumatic regulator and a manual airflow control valve. The results showed that both types of regulators are suitable for the stable generation of monodisperse droplets for at least 4 h, with variations in diameter less than 1 µm. Droplet diameters at high levels of negative pressure were mainly determined by the hydrodynamic resistances of the inlet microchannels, although the absolute pressure value defined the generation frequency; however, the electro-pneumatic regulator is preferable and convenient for the accurate control of the pressure by an external electric signal, providing more stable pressure, and a wide range of droplet diameters and generation frequencies. The method of droplet generation suggested here is a simple, stable, reliable, and portable way of high-throughput production of relatively large volumes of monodisperse emulsions for biomedical applications. Full article

A Printed Circuit Heat Exchanger (PCHE) is a type of highly complete and efficient heat exchanger that consists of numerous mini/micro-channels and has been successfully applied to the Liquefied Natural Gas (LNG) regasification project. During the research presented in this paper, the condensation flow and heat transfer performance of the R22 in PCHE hot side minichannels are analyzed via experiments and numerical simulations, respectively. A liquid nitrogen–R22 experimental loop is established to examine the pressure difference and heat transfer coefficient of R22 in the minichannels of the PCHE hot side. The inlet pressures of the R22 range from 0.5 MPa to 0.65 MPa, the mass flux values are changed from 10.52 ${\mathrm{kg}\mathrm{m}}^{-2}{\mathrm{s}}^{-1}$ to 109.42${\mathrm{kg}\mathrm{m}}^{-2}{\mathrm{s}}^{-1}$, and the inlet temperatures vary from 273 K to 289 K. The differences between experiments and simulations are analyzed by comparing the experimental values of the Nusselt number (Nu) and the friction pressure gradient with the numerical ones. Furthermore, the influences of pressure and mass flux on the Nu, as well as the friction pressure gradient, are analyzed in depth through condensation flow regimes to explore the underlying mechanism giving the results. Full article

Nowadays, cooling high thermal flows in compact volumes continues to be one of the crucial problems in the industry. With the advent of advanced technologies, much more attention has been paid to how to improve the performance of cooling systems in the area of micro-technologies. Rectangular mini-channels are typical representatives which commonly used for cooling applications. However, micro-technologies still face the problem of low performance due to the low productivity of cooling related to unbefitting physical parameter values. Here, this work studies the applicability of the heat transfer scheme of convective flow and flow boiling in a rectangular mini-channel for satisfying the cooling requirement of industrial micro-technologies, through a simulation model governed by the coupled mechanism from Navier-Stokes (N-S) equation and heat transfer equations with phase change effect. In this work, various hydraulic diameters and different inlet fluid speed are used to calculate the different velocity profiles, pressure drops, coefficients of friction and finally, the distribution of the temperatures and dissipated heat flux. The simulation results show the applicability of the rectangular mini-channel in diverse applications such as engine cooling, electronic components, automotive on-board electronics and aerospace engineering. Flow boiling simulation results reveal that the obtained patterns were smooth mixture flow and discrete flow. The dissipated heat flux can reach 1.02–5.34 MW/m² for a hydraulic diameter of 0.5 mm. We show that the system with the gradient temperature that evolves increasingly along the top and bottom walls of the channels presents the highest heat flux dissipated in flow boiling. Additionally, the fin efficiency of the system is 0.88 and the coefficient value of convective heat transfer is in the range between 5000 < h < 100,000, which indicates the flow boiling heat transfer is effective in the mini-channel when the Reynolds number is less than 400. It provides a significant heat exchange for cooling in these application areas. Full article

We develop a strategy for preparing water-based dispersions of polymer/TiO₂ nanospheres that can be used to form composite materials applicable in various fields. The formed hybrid nanospheres are monodisperse and possess a hierarchical structure. It starts with the primary TiO₂ nanoparticles of about 5 nm, which first assemble to nanoclusters of about 30 nm and then are integrated into monomer droplets. After emulsion polymerization, one obtains the water-based dispersions of polymer/TiO₂ nanospheres. To achieve universal size, it is necessary to have treatments with intense turbulent shear generated in a microchannel device at different stages. In addition, a procedure combining synergistic actions of steric and anionic surfactants has been designed to warrant the colloidal stability of the process. Since the formed polymer/TiO₂ nanospheres are stable aqueous dispersions, they can be easily mixed with TiO₂-free polymeric nanoparticle dispersions to form new dispersions, where TiO₂-containing nanospheres are homogeneously distributed in the dispersions at the nanoscale, thus leading to various applications. As an example, the proposed strategy has been applied to generate polystyrene/TiO₂ nanospheres of about 100 nm in diameter. Full article