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Graphical abstract Highlights • Flow boiling in two thermally isolated parallel microchannels is studied experimentally. • Boiling incipience in one channel triggers the Ledinegg instability. • The Ledinegg instability induces a temperature excursion due to flow maldistribution. • When the second channel also experiences boiling incipience, the Ledinegg instability is suppressed. Abstract Two-phase flow through heated parallel channels is commonly encountered in thermal systems used for power generation, air conditioning, and electronics cooling. Flow boiling is susceptible to instabilities that can lead to maldistribution between the channels and thereby heat transfer performance reductions. In this study, the Ledinegg instability that occurs during flow boiling in two thermally isolated parallel microchannels is studied experimentally. A dielectric liquid (HFE-7100) is delivered to the parallel channels using a constant pressure source. Both channels are uniformly subjected to the same power, which is in increased in steps. Flow visualization is conducted simultaneously with pressure drop, mass flux, and wall temperature measurements to characterize the thermal-fluidic effects of the Ledinegg instability. When the flow in both channels is in the single-phase regime, they have equal wall temperatures due to evenly distributed mass flux delivered to each channel. Boiling incipience in one of the channels triggers the Ledinegg instability which induces a temperature difference between the two channels due to flow maldistribution. The temperature difference between the two channels grows with increasing power until boiling incipience occurs in the second channel. The wall temperatures of both channels then reduce significantly as the flow becomes more evenly distributed. The experimentally observed temperature excursion between the channels is reported here for the first time and provides an improved understanding of the thermal performance implications of the Ledinegg instability in thermally isolated parallel channels. [ABSTRACT FROM AUTHOR]

Dynamic instabilities during flow boiling in a uniformly heated microchannel are investigated. The focus of this Part 2 of the study is on the effect of operating conditions on the instability type and the resulting time-periodic hydrodynamic and thermal oscillations, which have been established after the initial boiling incipience event. Part 1 of this study investigated the rapid-bubble-growth instability at the onset of boiling in the same experimental facility. Fluid is driven through the single 500 μm-diameter glass microchannel by maintaining a constant pressure difference between a pressurized upstream reservoir and a reservoir downstream that is open to the ambient, so as to resemble the hydrodynamic boundary conditions of an individual channel in a parallel-channel heat sink. Simultaneous high-frequency measurement of pressure drop, mass flux, and wall temperature is synchronized to high-speed flow visualizations enabling transient characterization of the thermal-fluidic behavior. The effect of flow inertia, inlet liquid subcooling, and heat flux on the hydrodynamic and thermal oscillations and time-averaged performance is assessed. Two predominant dynamic instabilities are observed: a time-periodic series of rapid-bubble-growth instabilities, and the pressure drop instability. A spectral analysis of the time-periodic data is performed to determine the characteristic oscillation frequencies. The heat flux, ratio of flow inertia to upstream compressibility, and degree of inlet liquid subcooling significantly affect the thermal-fluidic characteristics. High inlet liquid subcoolings and low heat fluxes result in time-periodic transitions between single-phase flow and flow boiling that cause large-amplitude wall temperature oscillations due to a time-periodic series of rapid-bubble-growth instabilities. Low inlet liquid subcoolings result in small-amplitude thermal-fluidic oscillations and the pressure drop instability. Low flow inertia exacerbates the pressure drop instability and results in large-amplitude thermal-fluidic oscillations whereas high flow inertia reduces their severity. [ABSTRACT FROM AUTHOR]

Dynamic flow boiling instabilities are studied experimentally in a single, 500 µm-diameter glass microchannel subjected to a uniform heat flux. Fluid flow is driven through the microchannel in an open-loop test facility by maintaining a constant pressure difference between a pressurized upstream reservoir and a reservoir at the exit that is open to the ambient; the working fluid is HFE-7100. This hydrodynamic boundary condition resembles that of an individual channel in a parallel-channel heat sink where the channel mass flux can vary in time. Simultaneous high-frequency measurement of reservoir, inlet, and outlet pressures, pressure drop, mass flux, inlet and outlet fluid temperatures, and wall temperature is synchronized to high-speed flow visualizations enabling transient characterization of the thermal-fluidic behavior. Part 1 of this study investigates the rapid-bubble-growth instability at the onset of boiling; the effect of flow inertia and inlet liquid subcooling is assessed. The mechanisms underlying the rapid-bubble-growth instability, namely, a large liquid superheat and a large pressure spike, are quantified; this instability is shown to cause flow reversal and can result in large temperature spikes. Low flow inertia exacerbates the rapid-bubble-growth instability by starving the heated channel of liquid replenishment for longer durations and results in severe temperature increases. In the case of high flow inertia or high inlet liquid subcooling, flow reversal is still observed at the onset of boiling, but results in a minimal wall temperature rise because liquid quickly replenishes the heated channel. A companion paper (Part 2) investigates the effect of flow inertia, inlet liquid subcooling, as well as heat flux on the thermal-fluidic oscillations during time-periodic flow boiling that follows the initial incipience at the onset of boiling considered here. [ABSTRACT FROM AUTHOR]

This study uses high-speed imaging to characterize microchannel slug flow boiling using a novel experimental test facility that generates an archetypal flow regime suitable for high-fidelity characterization of key hydrodynamic and heat transfer parameters. Vapor and liquid phases of the fluorinated dielectric fluid HFE-7100 are independently injected into a T-junction to create a saturated two-phase slug flow, thereby eliminating the flow instabilities and flow-regime transitions that would otherwise result from stochastic generation of vapor bubbles by nucleation from a superheated channel wall. Slug flow boiling is characterized in a heated, 500 μm-diameter borosilicate glass microchannel. A thin layer of optically transparent and electrically conductive indium tin oxide coated on the outside surface of the microchannel provides a uniform heat flux via Joule heating. High-speed flow visualization images are analyzed to quantify the uniformity of the vapor bubbles and liquid slugs generated, as well as the growth of vapor bubbles under heat fluxes ranging from 30 W/m 2 to 5160 W/m 2 . A method is demonstrated for measuring liquid film thickness from the visualizations using a ray-tracing procedure to correct for optical distortions. Characterization of the slug flow boiling regime that is generated demonstrates the unique ability of the facility to precisely control and quantify hydrodynamic and heat transfer characteristics. The experimental approach demonstrated in this study provides a unique platform for the investigation of microchannel slug flow boiling transport under controlled, stable conditions suitable for model validation. [ABSTRACT FROM AUTHOR]

Granular flows are commonly encountered in many industrial processes, but are difficult to characterize due to the opaque nature of the flow. For instance, screw pyrolyzers are being developed for the thermochemical conversion of biomass into bio-oil, but the granular flow and mixing process inside the reactor lacks fundamental understanding. In this study, X-ray particle tracking velocimetry (XPTV) is used to qualitatively and quantitatively characterize the three-dimensional (3D) granular flow structures in a double screw mixer, which geometrically replicates double screw pyrolyzers, by visualizing the position and speed profiles and quantifying the dimensionless pathlength and dimensionless residence time of individual tracer particles. The influence of screw rotation speed, dimensionless screw pitch, screw rotation orientation, and material injection configuration are investigated. Certain operating conditions are shown to significantly influence the granular flow structures and, in some instances, cause the double screw mixer to behave similar to two single screw conveyors. Comparisons with previous granular mixing studies are made to provide a link between granular flow behavior and mixing effectiveness. [ABSTRACT FROM AUTHOR]

Granular mixing processes often seek a high degree of homogeneity and, in some instances, can influence simultaneous processing, such as chemical reactions and heat and/or mass transfer. However, specific operating conditions and differences in particle size, shape, and/or density lead to segregation and reduce the mixing effectiveness of these processes. In this study, red oak chips and glass beads are mechanically mixed using a laboratory-scale double screw mixer and the mixing effectiveness is evaluated under various operating conditions. Qualitative optical visualization from four spatially aligned and temporally synced projections is combined with quantitative composition and statistical analysis techniques to optimize and investigate the influence of different operating conditions on the mixing effectiveness of the screw mixer. For the parameters considered in this study, the best mixing performance occurs when the screw rotation speed is ω = 60 rpm, the dimensionless screw pitch is p/D = 1.75, the screw rotation orientation is counter-rotating down-pumping, and the material injection configuration features the red oak chips and glass beads injected into port one and two, respectively. [ABSTRACT FROM AUTHOR]

Characterizing multiphase or granular flows is difficult due to the opaque nature of the system. While invasive measurement techniques provide detailed information about a single point, assessing the entire system is a laborious task due to the large number of samples required. Therefore, significant work has gone into developing noninvasive methods of measuring these flow systems. In this study, identical pairs of X-ray source/detector systems are used to provide two simultaneous but independent X-ray radiographic projections, which are then coupled together to perform X-ray stereographic imaging of a granular flow. A cone-beam compensated back-projection algorithm is developed for X-ray particle tracking velocimetry (XPTV). This method accurately corrects for the X-ray׳s cone-beam geometry, which is ignored in parallel-beam back-projection methods. To demonstrate the need for the cone-beam compensation, a direct comparison between the cone-beam and parallel-beam back-projection algorithms is used, and significant differences are presented. These methods are then used to perform XPTV in a double screw mixer, allowing the position and velocity of individual tracer particles to be characterized. [ABSTRACT FROM AUTHOR]

Abstract: The mixing of granular materials has a significant influence on the yield and/or quality of the desired products in numerous industrial processes including energy generation, food processing, and pharmaceutical production. However, characterizing the mixing effectiveness of systems or processes in granular applications is difficult due to challenging sampling procedures and measurement techniques. In this study, a two-part measurement technique consisting of optical visualization and composition analysis is developed to provide qualitative and quantitative mixing characteristics of continuous granular mixing processes, respectively. Mixing studies are performed in a laboratory-scale double screw mixer using a binary mixture of 500–6350μm red oak chips and 300–500μm glass beads. The effect of screw rotation speed and dimensionless screw pitch on the mixing effectiveness is investigated for ω=20, 40, and 60rpm and p/D=0.75, 1.25, and 1.75, respectively. Optical visualization in terms of video capture is captured across the entire mixing region's periphery, providing extensive qualitative observations. Quantitative composition analysis is performed on samples collected across the screw mixer and a two-way analysis of variance (ANOVA) statistical model is applied. Overall, the mixing effectiveness is maximized at an intermediate screw rotation speed of ω=40rpm and a dimensionless screw pitch of p/D=1.75. The developed measurement techniques and resulting trends are compared to previous granular mixing studies featuring similar mixing equipment found in the literature. [Copyright &y& Elsevier]

• Microchannel flow boiling under transient heating conditions is studied experimentally. • High-frequency sensor measurements are synchronized to flow visualizations. • Heat flux is pulsed between 15, 75, and 150 kW/m2 using a thin film heater. • The dynamic response to a transient pulse is qualitatively similar to that of a spring-mass-damper system. • Heat flux pulses that induce/arrest boiling cause a temporary wall temperature over/under-shoot. Microchannel flow boiling is an attractive approach for the thermal management of high-heat-flux electronic devices that are often operated in transient modes. In Part 1 of this two-part study, the dynamic response of a heated 500 μm channel undergoing flow boiling of HFE-7100 is experimentally investigated for a single heat flux pulse. Three heat flux levels exhibiting highly contrasting flow behavior under constant heating conditions are used: a low heat flux corresponding to single-phase flow (15 kW/m2), an intermediate heat flux corresponding to continuous flow boiling (75 kW/m2), and a very high heat flux which exceeds critical heat flux and would cause dryout if applied continuously (150 kW/m2). Transient testing is conducted by pulsing between these three heat flux levels and varying the pulse duration. High-frequency measurements of heat flux, wall temperature, pressure drop, and mass flux are synchronized to high-speed flow visualizations to characterize the boiling dynamics during the pulses. At the onset of boiling, the dynamic response resembles that of an underdamped mass-spring-damper system subjected to a unit step input. During transitions between single-phase flow and time-periodic flow boiling, the wall temperature temporarily over/under-shoots the eventual steady operating temperature (e.g. , by up to 20 °C) thus demonstrating that transient performance can extend beyond the bounds of steady performance. It is shown that longer duration high-heat-flux pulses (up to ~50% longer in some cases) can be withstood when the fluid in the microchannel is initial boiling, relative to if it is initially in the single-phase flow regime, despite being at an initially higher heat flux and wall temperature prior to the pulse. [ABSTRACT FROM AUTHOR]

• The effects of heating pulse frequency on flow boiling are studied experimentally. • Flow boiling performance and transient heating characteristics are heavily coupled. • Time-periodic flow regime transitions can occur for heating pulse frequencies >1 Hz. • Pressure drop oscillations sync to the transient heating profile for 1 < f < 10 Hz. • Above a heating pulse frequency of 25 Hz, the fluid effectively experiences a constant heat flux. Flow boiling in microchannels is an effective method for dissipating high heat fluxes. However, two-phase heat sink operation during transient heating conditions remains relatively unexplored. In Part 1 of this two-part study, the dynamic response of flow boiling to a single heat flux pulse was experimentally studied. In this Part 2, the effect of heating pulse frequency on microchannel flow boiling is explored when a time-periodic series of pulses is applied to the channel. HFE-7100 is driven through a single 500 μm-diameter glass microchannel using a constant pressure reservoir. A thin indium tin oxide layer on the outside surface of the microchannel enables simultaneous transient heating and flow visualization. High-frequency measurements of heat flux, wall temperature, pressure drop, and mass flux are synchronized to the flow visualizations to characterize the boiling process. A square-wave heating profile is used with pulse frequencies ranging from 0.1 to 100 Hz and three different heat fluxes levels (15, 75, and 150 kW/m2). Three different time-periodic flow boiling fluctuations were observed for the heat flux levels and pulse frequencies investigated in this study: flow regime transitions, pressure drop oscillations, and heating pulse propagation. For heat flux pulses between 15 and 75 kW/m2 and heating pulse frequencies above 1 Hz, time-periodic flow regime transitions between single-phase and two-phase flow are reported. For heating profiles involving 150 kW/m2 heat flux pulses, fluid in the microchannel is always boiling and thus the flow regime transitions are eliminated. For heating pulse frequencies between approximately 1 and 10 Hz, the thermal and flow fluctuations are heavily coupled to the heating characteristics, forcing the pressure drop instability frequency to match the heating frequency. Outside this heating pulse frequency range, the pressure drop instability occurs at the intrinsic frequency of the system. For heating pulse frequencies above 25 Hz, the microchannel wall attenuates the transient heating profile and the fluid essentially experiences a constant heat flux. [ABSTRACT FROM AUTHOR]