Issam Mudawar — Page 2

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Validation of Universal Cryogenic Flow Boiling Correlations in Thermal Desktop for Liquid Methane and Liquid Nitrogen

Future in-space cryogenic architectures will depend on the ability to accurately model various stages of cryogenic propellant transfer and storage. Currently there is a need for more accurate, direct cryogenic data-anchored models for various boiling phenomena. This paper presents the implementation and validation of recently developed universal cryogenic flow boiling correlations for saturated flow boiling heat transfer coefficients (HTC) and critical heat flux (CHF) into the Thermal Desktop (SINDA/FLUINT) modeling software. The correlations are validated against steady state cryogenic flow boiling historical heated tube cases from liquid nitrogen and liquid methane experiments covering a wide range of inlet conditions, mass flux, and heat flux. Overall, Thermal Desktop with the new universal cryogenic flow boiling correlations demonstrates significant improvement in predictive performance for both wall temperature and CHF location compared to the Thermal Desktop model with built-in correlations when both are compared to the data.

Mariano Mercado↗

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Flow Boiling and Condensation Experiment: Flow Boiling in a Rectangular Channel with Subcooled Inlet Conditions in Microgravity

Two-phase thermal management subsystems that take advantage of both the sensible and latent heat of a working fluid can potentially yield significant enhancements in overall performance by adopting heat transfer processes that are based on phase transition like boiling and condensation. Performance of terrestrial two-phase flow systems may be predictable because the hydrodynamic and body forces are understood, however, in microgravity, which is predominant during planetary space travel, forces that are masked by the strong body force on Earth (gravitational or buoyancy force) reappear with different magnitude and influence. The need arose for a facility that provides for two-phase flow with phase transition testing in microgravity. The Flow Boiling and Condensation Experiment (FBCE) is a facility that was launched to the International Space Station in August of 2021 and is in operation since February of 2022. This facility enables investigators to perform two-phase flow and phase transition research in flow boiling and condensation. Along with the test module that is experiment specific, the FBCE system consists of the fluid, avionics, and software subsystems. Currently two test modules, namely, the Flow Boiling Module (FBM) and the Condensation Module for Heat Transfer (CM-HT) are available. A third module, the Transfer Line test Module (TL) is being developed. The fluid subsystem conditions and delivers the fluid at the desired thermodynamic state to the test module. It consists of two fluid modules and a heater module that are connected by flex hoses for fluid circulation and by data and electrical cables for control and data acquisition. Two avionics modules acquire pressure and temperature data from various sensors in the flow loop. For FBM, a high-speed camera is available to acquire images of the boiling process. Experiments are operated autonomously by software and are based on an Experiment Parameters Master Table (EPMT) that is uploaded to ISS and is executed by the FBCE flight software. This presentation briefly introduces the objectives of FBCE and provides a system description of the experiment onboard of the ISS/Fluid Integrated Rack (FIR). Results of the test campaign carried out using the FBM are presented. Specifically, microgravity flow boiling of n-perfluorohexane (test fluid) is discussed with subcooled inlet conditions in a single-side-heated rectangular channel of dimensions 114.6-mm heated length, 2.5-mm heated width, and 5.0-mm height. Key operating parameters investigated are mass velocity (199.90 – 3200.13 kg/m2s), inlet subcooling (0.10 – 45.76°C), and inlet pressure (113.30 – 164.29 kPa). Image sequences acquired via high-speed-video are shown to elucidate the interfacial flow physics. The effects of various parameters on flow boiling heat transfer in microgravity, from the onset of boiling to the critical heat flux are discussed. Heat transfer results are presented in terms of flow boiling curves, streamwise profiles of wall temperature and heat transfer coefficient, and parametric trends of local and averaged heat transfer coefficient, and the critical heat flux.

Two-phase flow and phase transition↗

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Flow Boiling and Condensation Experiment (FBCE): Summary of Findings for Flow Boiling based on Completed ISS Experiments

Since 2011, researchers from Purdue University and NASA Glenn Research Center (GRC) have been collaborating to investigate the effects of gravity on several aspects of flow boiling and flow condensation. This massive research endeavor, termed the Flow Boiling and Condensation Experiment (FBCE), has culminated in development of NASA’s largest and most complex facility for investigation of two-phase fluid physics onboard the ISS. FBCE consists of two separate studies: flow boiling, using the Flow Boiling Module (FBM), and flow condensation, using the Condensation Module for Heat Transfer Measurements (CM-HT); this presentation concerns the FBM portion of FBCE. Fitted with FBM, FBCE was launched to the ISS in August 2021 and experiments were successfully performed starting in February 2022 to amass a large microgravity-flow-boiling database supported by extensive visualization of interfacial behavior using high-speed video. Based on FBCE experiments performed previously in Earth gravity and parabolic flight, along with the new ISS data, several empirical correlations, theoretical models, and CFD models have been developed, enabling the prediction of crucial flow boiling parameters, including heat transfer coefficient and critical heat flux (CHF). These predictive tools, which will be summarized in this presentation, are expected to serve as foundation for design of future space systems involving flow boiling.

Two-phase flow and phase transition↗

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Cryogenic Flow Boiling Parabolic Flight Experiment and Universal Correlations for Cryogens

Cryogenic fluids are employed in many industries and play crucial roles in space applications, including nuclear thermal propulsion systems, LOX/LCH4 ascent and descent stage feedlines, LOX/LH2 transfer lines for in-space fuel depots, and LHe transfer lines that cool space experiments. Due to the ultra-low boiling point of cryogens, phase change is inevitable in these systems, which leads to complex boiling behavior in reduced gravity. For cost-effective design and sizing of the aforementioned systems, accurate knowledge of two-phase parameters such as pressure drop, heat transfer coefficient (HTC), and critical heat flux (CHF) is desired. Since 2018, researchers from Purdue University and NASA Glenn Research Center (GRC) have been collaborating to investigate the effects of reduced gravity on cryogenic pool boiling, flow boiling ins tubes, and spray cooling. Using a variety of both terrestrial and parabolic flight experimental rigs, extensive LN2 data have been amassed and combined with cryogenic data from World literature to develop both ‘universal’ empirical correlations and CFD models, which are expected to serve as foundation for design of future space systems involving cryogenic fluids. This presentation will provide an overview of both the experimental work and predictive tools that have resulted from the joined Purdue-Glenn studies.

Flow Boiling↗

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Validation of Universal Cryogenic Flow Boiling Correlations in Thermal Desktop for Liquid Hydrogen

Developing accurate models of two-phase cryogenic flow will reduce risk and reduce margins for future NASA vehicles such as the Nuclear Thermal Propulsion (NTP) system. Currently there is a need for more accurate, direct cryogenic data-anchored models for various boiling and two-phase phenomena. The focus of the current work is on modeling steady state cryogenic flow boiling in the transfer line that connects a propellant storage tank to an engine or customer receiver tank. This paper presents Thermal Desktop model validation results against several historical liquid hydrogen (LH2) heated tube experiments that cover a wide range of inlet conditions, mass flux, and heat flux. New universal cryogenic flow boiling correlations were recently developed and anchored to the largest cryogenic flow boiling database assembled in the world to-date. The new universal correlations are patched together and implemented into Thermal Desktop to compare model performance against the built-in flow boiling correlations. Axial wall temperature predictions as a function of preponderant parameters like heat flux, mass flux, inlet pressure, inlet quality, tube diameter, etc. using the two sets of flow boiling correlations are compared against the experimental data. Overall, the Thermal Desktop model with the new universal cryogenic flow boiling correlations demonstrates an improvement in predictive performance over the Thermal Desktop model using built-in correlations for both wall temperature and location of critical heat flux compared to the data for LH2 flow boiling in heated tubes.

Cryogenic Propellant Transfer↗

NASA NTRSDate not supplied

Validation of Universal Cryogenic Flow Boiling Correlations in Thermal Desktop for Liquid Hydrogen

Developing accurate models of two-phase cryogenic flow will reduce risk and reduce margins for future NASA vehicles such as the Nuclear Thermal Propulsion (NTP) system. Currently there is a need for more accurate, direct cryogenic data-anchored models for various boiling and two-phase phenomena. The focus of the current work is on modeling steady state cryogenic flow boiling in the transfer line that connects a propellant storage tank to an engine or customer receiver tank. This paper presents Thermal Desktop model validation results against several historical liquid hydrogen (LH2) heated tube experiments that cover a wide range of inlet conditions, mass flux, and heat flux. New universal cryogenic flow boiling correlations were recently developed and anchored to the largest cryogenic flow boiling database assembled in the world to-date. The new universal correlations are patched together and implemented into Thermal Desktop to compare model performance against the built-in flow boiling correlations. Axial wall temperature predictions as a function of preponderant parameters like heat flux, mass flux, inlet pressure, inlet quality, tube diameter, etc. using the two sets of flow boiling correlations are compared against the experimental data. Overall, the Thermal Desktop model with the new universal cryogenic flow boiling correlations demonstrates an improvement in predictive performance over the Thermal Desktop model using built-in correlations for both wall temperature and location of critical heat flux compared to the data for LH2 flow boiling in heated tubes.

cryogenic propellant transfer↗

NASA NTRSDate not supplied

Flow Boiling and Condensation Experiment (FBCE): Latest Findings from the Summary ISS Experiments

Since 2011, researchers from Purdue University and NASA Glenn Research Center (GRC) have been collaborating to investigate the effects of gravity on several aspects of flow boiling and flow condensation. This massive research endeavor, termed the Flow Boiling and Condensation Experiment (FBCE), has culminated in development of NASA’s largest and most complex facility for investigation of two-phase fluid physics onboard the ISS. FBCE consists of two separate studies: flow boiling, using the Flow Boiling Module (FBM), and flow condensation, using the Condensation Module for Heat Transfer Measurements (CM-HT); the FBM experiments have already been completed while the condensation experiments began in 2024. This presentation will summarize mostly new results from the flow boiling experiments, with a focus on analysis of pressure drop and two-phase flow instabilities in microgravity using both experimental data and video records from the ISS experiments, as well as development of machine learning models. These new predictive tools are part of the arsenal of predictive methods developed by the Purdue-Glenn team for design of future space systems.

Microgravity↗