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Local heat-transfer coefficients and static pressures for condensation of high-velocity steam within a tube
Local heat transfer and static pressure data for steam condensation in vertical downflow tube
Technoeconomic Benefits of Film-Forming Amine Products Applied to Steam Surface Condensers
In a conventional Rankine cycle, the majority of power plants employ surface condensers that use pumped cooling water to reject heat from the cycle. In such cases, heat rejection occurs in a shell and tube heat exchanger by film-wise condensation of low-pressure steam on stainless steel, titanium, brass, or copper-nickel tubing. To improve the thermal performance of steam surface condensers, a replenishable film-forming substance (FFS) can be ap-plied to the condenser tubing to promote efficient dropwise condensation. Conventionally, film-forming amine prod-uct (FFAP) coatings protect boiler surfaces from oxidative corrosion, which substantially reduces the operation and maintenance costs. To quantify the technical and economic benefits of FFAP coatings applied to condenser tubing due to the promotion of dropwise condensation, a thermal resistance network model was established. Using a rep-resentative steam surface condenser, the improvements in thermal performance (overall heat transfer coefficient) and process parameters (net plant efficiency, cooling water flowrate, and turbine backpressure) were determined due to the enhancement in the condensation heat transfer coefficient. Experimentally measured condensation heat transfer coefficients for common condenser materials were compared with the modeling results and were found to be within attainable bounds. Lastly, the trend in total heat exchanger cost reduction is generalized to understand the trade-off between reduced surface area for heat rejection and increase in coating application costs for a re-plenishable coating system.
Flow Boiling and Condensation Experiment Flight Hardware Development
The Flow Boiling and Condensation Experiment (FBCE) to be manifested on the International Space Station (ISS) consists of a fluid system and the associated electronics to provide for conditioning the test fluid (normal-PerFluorohexane or nPFH-C6F14) to the proper thermodynamic state prior to entering a test module, which can be interchangeable based on the science objectives. Two separate test modules have been manufactured for the FBCE, the Flow Boiling Module (FBM), which investigates flow boiling for a subcooled liquid, saturated liquid, or two phase mixture, and the Condensation Module Heat Transfer (CM-HT), which investigates condensation of a flowing saturated or superheated vapor. The test fluid heating is accomplished using the Bulk Heater Module (BHM), which heats the fluid to various states based on the demands of the currently installed test module. ISS Internal Thermal Control System (ITCS) water is utilized to cool the test fluid prior to entering the circulation pump, and is also utilized for cooling for condensation in CM-HT, for cooling of a camera in FBM. An adjustable pressure bellows-type accumulator is used to set the pressure at the inlet of the test section, but does not provide active pressure control during testing. The flow of the test fluid is achieved using a gear pump controlled by a coriolis flow meter, which also provides the flow rate measurement. Flow rates for the ITCS water loops are measured and controlled using coriolis flow meters with directly controlled proportional valves. During execution of FBCE operations, the FBM is scheduled to collect data for three months before being exchanged with CM-HT for another three month data collection run. In this work, we present the development of the flight hardware, the associated challenges experienced during the development such as packaging flight system hardware, and the lessons learned in overcoming the encountered challenges.
Performance evaluation of a wrapped around condenser for heat pump water heater applications
In this report, accurate performance evaluation of a wrapped-around condenser for heat pump water heaters (WHPWH) is critical since the COP of the system depends heavily on thermal stratification and condenser design. An analytical, quasi-steady state heat balance method has been developed to determine the optimal spacing between adjacent channels, tube diameter, tube shape, and total refrigerant charge amount for the condenser. The heat transfer rate is compared among three approaches: the refrigerant thermodynamic model, the condenser-wrap fin model, and the analytical natural convection model on the inside of the tank for the three regions based on the refrigerant phase (e.g., super-heated, saturated, or subcooled). The heat transfer rate was predicted by a combination of slug-plug and annular flow for a D-shaped helical tube. Experimental data were used as boundary conditions for validating the model. The rate of heat transfer based on tube shape and tank wall temperatures was compared by CFD analysis. Parametric analysis indicates a tradeoff between refrigerant mass, pressure drop, tube diameter, and tube length to maximize the heat transfer rate. The model suggests the saturated region length can be extended by 400%, and the condenser pressure drop can be reduced by 23% with an optimal spacing pattern.
ALKALI METALS BOILING AND CONDENSING INVESTIGATIONS
Two phase heat transfer data for sodium and potassium under conditions of boiling and condensing
Local heat-transfer and pressure distributions for Freon-113 condensing in downward flow in a vertical tube
Local heat-transfer data and static-pressure distributions for Freon-113 condensing inside vertical tube
Development of a condenser for the dual catalyst water recovery system
Conceptual evaporation/condensation systems suitable for integration with the catalytic water recovery method were evaluated. The primary requirements for each concept were its capability to operate under zero-gravity conditions, condense recovered water from a vapor-noncondensable gas mixture, and integrate with the catalytic system. Specific energy requirements were estimated for concepts meeting the primary requirements, and the concept most suitable for integration with the catalytic system was proposed. A three-man rate condenser capable of integration with the proposed system, condensing water vapor in presence of noncondensables and transferring the heat of condensation to feed urine was designed, fabricated, and tested. It was treated with steam/air mixtures at atmospheric and elevated pressures and integrated with an actual catalytic water recovery system. The condenser has a condensation efficiency exceeding 90% and heat transfer rate of approximately 85% of theoretical value at coolant temperature ranging from 7 to 80 deg C.
Film Condensation with and Without Body Force in Boundary-Layer Flow of Vapor Over a Flat Plate
Laminar film condensation under the simultaneous influence of gas-liquid interface shear and body force (g force) is analyzed over a flat plate. Important parameters governing condensation and heat transfer of pure vapor are determined. Mixtures of condensable vapor and noncondensable gas are also analyzed. The conditions under which the body force has a significant influence on condensation are determined.
Novel Patterned Surfaces for Improved Condenser Performance in Power Plants
In this project, we seek to improve the thermoelectric power plant performance through engi-neered nonwetting condenser tube surface designs that can enhance heat transfer performance by: (1) promoting dropwise condensation of the steam on the shell side and eliminating flooding of the surface structure by maintaining low droplet adhesion, thus increasing condensation heat transfer coefficient; (2) deterring fouling and corrosion, thereby reducing fouling resistance and improving heat transfer; (3) possibly reducing drag and increasing convective heat transfer inside coolant tubes; and (4) reducing the number of tubes, coolant water usage, and levelized cost of condenser.
Gravity Effects in Condensing and Evaporating Films
A general overview of gravity effects in condensing and evaporating films is presented. The topics include: 1) Research Overview; 2) NASA Recognizes Critical Need for Condensation & Evaporation Research to Enable Human Exploration of Space; 3) Condensation and Evaporation Research in Reduced Gravity is Enabling for AHST Technology Needs; 4) Differing Role of Surface Tension on Condensing/Evaporating Film Stability; 5) Fluid Mechanisms in Condensing and Evaporating Films in Reduced Gravity; 6) Research Plan; 7) Experimental Configurations for Condensing Films; 8) Laboratory Condensation Test Cell; 9) Aircraft Experiment; 10) Condensation Study Current Test Conditions; 11) Diagnostics; 12) Shadowgraph Images of Condensing n- pentane Film in Unstable (-1g) Configuration; 13) Condensing n-Pentane Film in Normal Gravity (-1g) at Constant Pressure; 14) Condensing n-Pentane Film in Normal Gravity (-1g) with Cyclic Pressure; 15) Non-condensing Pumped Film in Normal Gravity (-1g); 16) Heat Transfer Coefficient in Developing, Unstable Condensing Film in Normal Gravity; 17) Heat Transfer for Unsteady Condensing Film (-1g); 18) Ultrasound Measurement of Film Thickness N-pentane Film, Stable (+1g) Configuration; and 19) Ultrasound Measurement of Film Thickness N-pentane Film, Unstable (-1g) Configuration.
Analysis of Cryogenic Propellant Liquefaction Rates in Cooled Constant-Wall-Temperature Tanks
NASA has been focused on developing technology that would allow the production of cryogenic propellants on the Lunar and Martian surfaces. Utilizing Lunar/Martian resources, the produced gaseous propellants must first be liquefied and stored prior to use on the Moon or Mars ascent vehicle. Liquefaction of cryogenic propellant is a necessary technical development to enable NASA’s future spaceflight goals. This paper presents an overview of the effect of spacecraft propellant system parameters on cryogenic propellant liquefaction rates. The propellant system was assumed to be a receiver of a gas from an In-Situ Resource Utilization (ISRU) harvester and condensed the gas by cooling the tank walls. First, the general thermodynamic principles pertinent to condensation are summarized, followed by an overview of the model which performed the analysis, including a summary of the Fortran implementation. Comparisons between the model results and test data are discussed, as well as sensitivity of the condensation rate to various parameters.
Analysis of Cryogenic Propellant Liquefaction Rates in Cooled Constant-Wall-TemperatureTanks
NASA has been focused on developing technology that would allow the production of cryogenic propellants on the Lunar and Martian surfaces. Utilizing Lunar/Martian resources, the produced gaseous propellants must first be liquefied and stored prior to use on the Moon or Mars ascent vehicle. Liquefaction of cryogenic propellant is a necessary technical development to enable NASA’s future spaceflight goals. This paper presents an overview of the effect of spacecraft propellant system parameters on cryogenic propellant liquefaction rates. The propellant system was assumed to be a receiver of a gas from an In-Situ Resource Utilization (ISRU) harvester and condensed the gas by cooling the tank walls. First, the general thermodynamic principles pertinent to condensation are summarized, followed by an overview of the model which performed the analysis, including a summary of the Fortran implementation. Comparisons between the model results and test data are discussed, as well as sensitivity of the condensation rate to various parameters.
Freeze range of a condensing gas propagating in a liquid helium-cooled tube
Understanding air propagation and condensation following a catastrophic vacuum break in particle accelerator beamlines cooled by liquid helium is crucial for maintaining the operational safety of these facilities. Previous experimental investigations on nitrogen gas propagation in both normal liquid helium (He I) and superfluid helium (He II) cooled copper tubes unveiled a nearly exponential deceleration of the gas propagation. A comprehensive theoretical model incorporating gas dynamics, heat transfer, and condensation mechanisms has been developed, which effectively reproduces various key experimental observations. An intriguing phenomenon uncovered in our model simulation is that the gas propagation appears to nearly stop beyond a certain distance from the location where condensation starts. We refer to this distance as the freeze range. In this paper, we present our systematic study of the freeze range at various inlet mass fluxes and tube diameters. We show that the results can be well described by a simple correlation. The underlying physical mechanism that supports this useful correlation is explained. Knowing the freeze range may allow accelerator engineers to develop protocols for controlling frost-layer contamination in the beamline tubes, which is of great practical importance.
Modeling of Condensation in the Presence of Noncondensables in GFSSP
The Generalized Fluid System Simulation Program (GFSSP) computer code is enhanced with the capability to model condensation in the presence of noncondensable gases. Condensation in the presence of noncondensables is modeled using the Couette flow film (stagnant film) model. Experimental data on the condensation of water vapor in downward flow of air-water vapor and helium-water vapor mixtures in vertical tubes are compared with the predictions of GFSSP. The comparisons show that GFSSP can predict the experimental data well.
Numerical Simulation of No Vent Chill and Fill of a Large Liquid Hydrogen Tank
On orbit transfer of cryogenic liquids is necessary for many future space missions. The techniques required to transfer cryogens in micro gravity are quite different from ground system applications. In normal gravity, cryogenic tanks are usually filled from the bottom at nearly atmospheric pressure. The vapor generated due to heat transfer from warm tank walls, is allowed to vent from the top of the tank while the tank is being filled. If the normal gravity technique is used on orbit, the uncertainty of liquid and vapor distributions in unsettled condition may result in dumping of large amounts of liquid propellant overboard. The Vented Chill and No Vent Fill (VCNVF) process is a methodology [1] used to reduce propellant loss by holding the vent valve open during initial wall chilldown, preventing over-pressurization of the tank and stalling of the incoming flow, but closing the tank vent valve after chilling the tank wall sufficiently. An accurate simulation of no vent tank chill and fill is necessary to estimate the amount of propellant necessary to chill the tank, determine the maximum sustainable flowrate to fill the tank without stalling, and establish a timeline for the filling process. Numerical modeling of filling a cryogenic tank is complex because the flow is two-phase and the process involves both boiling and condensation with heat transfer between solid and fluid. In recent years, progress has been made to develop a numerical modeling technique [2,3,4] that has been verified by comparing with the test data from a small flight tank using liquid nitrogen [5]. The purpose of the present paper is to apply this technique in a larger tank with liquid hydrogen and compare with the test data of Chato [1]. The K-site Test Facility [1], shown in Figure 1, consists of a Test Tank, spray system, instrumentation, and the vacuum chamber. The test tank selected was ellipsoidal with an 87 inch major diameter and a 1.2 to 1 major to minor axis ratio. The two ends are joined by a short 1.5 inch cylindrical section. The tank is made of 2219 aluminum chemically milled to a nominal thickness of 0.087 inches. The tank weighs 329.25 pounds, and the tank volume is 175 ft 3 . The GFSSP model of the Test Tank is shown in Figure 2. Node 13 is a boundary node that represents the supply tank which is supplying liquid hydrogen at a given pressure and temperature. The total measured flowrate is evenly distributed through Branches 131 through 139. Nodes 1 through 9 represent the test tank and they are connected with metal solid nodes 14 through 22 through fluid-to-solid conductors that allow convective heat transfer between the solid and fluid nodes. The predicted tank pressure, filling rate, wall temperature and fluid temperature will be compared with test data.
Modeling of Condensation in the Presence of Noncondensables in GFSSP
The Generalized Fluid System Simulation Program (GFSSP) computer code is enhanced with the capability to model condensation in the presence of noncondensable gases. Condensation in the presence of noncondensables is modeled using the Couette flow film (stagnant film) model. Experimental data on the condensation of water vapor in downward flow of air-water vapor and helium-water vapor mixtures in vertical tubes are compared with the predictions of GFSSP. The comparisons show that GFSSP can predict the experimental data well.
Advances in understanding vacuum break dynamics in liquid helium-cooled tubes for accelerator beamline applications
Understanding air propagation and condensation following a catastrophic vacuum break in particle accelerator beamlines cooled by liquid helium is essential for ensuring operational safety. This review summarizes experimental and theoretical work conducted in our cryogenics lab to address this issue. Systematic measurements were performed to study nitrogen gas propagation in uniform copper tubes cooled by both normal liquid helium (He I) and superfluid helium (He II). These experiments revealed a nearly exponential deceleration of the gas front, with stronger deceleration observed in He II-cooled tubes. To interpret these results, a one-dimensional (1D) theoretical model was developed, incorporating gas dynamics, heat transfer, and condensation mechanisms. The model successfully reproduced key experimental observations in the uniform tube system. However, recent experiments involving a bulky copper cavity designed to mimic the geometry of a superconducting radiofrequency (SRF) cavity revealed strong anisotropic flow patterns of nitrogen gas within the cavity, highlighting limitations in extrapolating results from simplified tube geometries to real accelerator beamlines. To address these complexities, we outline plans for systematic studies using tubes with multiple bulky cavities and the development of a two-dimensional (2D) model to simulate gas dynamics in these more intricate configurations. As a result, these efforts aim to provide a comprehensive understanding of vacuum breaks in particle accelerators and improve predictive capabilities for their operational safety.