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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 19 records
All sourcesNASA NTRSDOE OSTI
DOE OSTI2021

Flow condensation heat transfer performance of natural and emerging synthetic refrigerants

There is great interest in predicting flow condensation heat transfer for lower global warming potential (GWP) fluids. This paper analyzes the efficacy of common flow condensation correlations developed for particular fluids in order to identify their suitability to predict heat transfer performance of low GWP fluids. Condensation heat transfer data were extracted from the literature, including 19 papers and 1,473 data points for natural refrigerants [i.e., ammonia (R717), CO 2 (R744), propane (R290), isobutane (R600a)] and 35 papers and 5,030 data points for synthetic refrigerants [i.e., R12, R1234yf, R1234ze(E), R1234ze(Z), R22, R32, R41, R123, R125, R134a, R142b, R152a, R161, R404A, R410A, R448A, R449A, R450A, R452B, R454C, R455A, R513A] encompassing tube diameters of 0.1–11.5 mm, mass fluxes of 55–1200 kg/m2s, and saturation temperatures of -25°C–65°C. Correlations analyzed included Akers et al. (1959), Cavallini et al. (2006, 2011), Kim and Mudawar (2013), Macdonald and Garimella (2016), Shah (1979, 2009, 2013, 2016) and Traviss et al. (1973) for smooth tubes and Chamra et al. (2005) and Kedzierski and Goncalves (1999) for enhanced tubes. Since most studies did not report wall temperature, correlations which relied on wall temperature directly or indirectly were excluded from the analysis. For synthetic refrigerants, mean average error (MAE) ranged from 6%–257%, and Cavallini et al. (2011) and Kim and Mudawar (2013) were the best predictors for emerging synthetic refrigerants. Furthermore, the Kim and Mudawar (2013) correlation was found to best predict the heat transfer performance for propane and R600a data, but most correlations did not accurately predict ammonia and CO 2 flow condensation.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
NASA NTRS1988

Study of toluene rotary fluid management device and shear flow condenser performance for a space-based organic Rankine power system

Management of two-phase fluid and control of the heat transfer process in microgravity is a technical challenge that must be addressed for an orbital Organic Rankine Cycle (ORC) application. A test program was performed in 1-g that satisfactorily demonstrated the two-phase management capability of the rotating fluid management device (RFMD) and shear-flow condenser. Operational tests of the RFMD and shear flow condenser in adverse gravity orientations, confirmed that the centrifugal forces in the RFMD and the shear forces in the condenser were capable of overcoming gravity forces. In a microgravity environment, these same forces would not have to compete against gravity and would therefore be dominant. The specific test program covered the required operating range of the Space Station Solar Dynamic Rankine Cycle power system. Review of the test data verified that: fluid was pumped from the RFMD in all attitudes; subcooled states in the condenser were achieved; condensate was pushed uphill against gravity; and noncondensible gases were swept through the condenser.

Havens, Vance↗
NASA NTRSDate not supplied

Acoustic Insights into Flow Condensation Mechanisms

Two-phase thermal management systems, with both boiling and condensation processes, offer great potential and heat transfer coefficients that are orders of magnitude higher than traditional single-phase systems. However, two-phase flows can suffer from a wide range of interfacial instabilities leading to significant thermal performance degradation. In this study, we aim to detect regime transitions and characterize dominating physical mechanisms of flow condensation, such as turbulent diffusion in annular liquid film and interfacial waves, using an integrated system of acoustic, modal, and optical sensing techniques and thermofluidic characterizations. A wideband acoustic emissions sensor and high-sensitivity accelerometer are utilized to capture acoustic and vibrational signatures that signal the onset of liquid film formation and interfacial waves during flow pattern transitions. Compared to optical imaging, wideband acoustic emission sensing allows for higher sampling rates to capture high-frequency interface oscillations critical to the flow regime transitions and works well even for condensation in opaque tubes. Acoustic features (e.g., amplitude, frequency, energy, duration) are correlated with thermofluidic processes (e.g., capillary flows, turbulent flows, boiling, condensation). By relating thermal performance metrics with these dynamic signatures in acoustic and modal regimes, we explore the ability to probe and monitor critical flow regime transitions and transport efficiency in flow condensation.

Acoustic Modal Regimes↗
DOE OSTI2025

Optimizing flow condensation models for next-generation refrigerants in axial micro-fin aluminum tubes

To support the transition to next-generation refrigerants, accurate modelling of heat transfer and pressure drop is essential for designing efficient heat exchangers. Current models, largely based on traditional refrigerants and unexpanded micro-fin tubes, may not reliably predict performance for new refrigerants and expanded micro-fin geometries. This study evaluates four condensation models using experimental data for six A2L refrigerants: R-32, R-454B, R-454C, R-455A, R-1234yf, and R-1234ze(E). For heat transfer models, the Han and Lee (2005) model initially yields the best accuracy (mean absolute Deviation, MAD = 22.1%). To further improve predictions, a correction factor reduces the Cavallini et al. (2009) model’s MAD from 68.2% to 15.4%, while optimization of the Kedzierski and Goncalves (1997) model achieves a MAD of 13.1%. For pressure drop, the Cavallini et al. (1997) model proves most accurate (MAD = 6.4%), with the simpler Haraguchi et al. (1993) model also effective (MAD = 9.4%). Keywords: Flow condensation models, heat transfer coefficient, frictional pressure drop, next-generation refrigerants, aluminum micro-fin tubes

Hu, Yifeng [ORNL] (ORCID:0000000242875185)↗
DOE OSTI2020

Benchmark of interfacial area concentration approaches for the two-fluid model in gas-dispersed condensing flow

Accurate predictions of interfacial area concentration (IAC) are required for closure of the condensation phase change term. The interfacial area transport equation (IATE) can dynamically predict interfacial area concentration and is increasingly being used in the benchmarking of phase change flows over static based correlations which require a flow regime map. For higher flow regimes, the two-group two-fluid IATE model can separately model the transport of spherical bubbles and cap/slug bubbles. Recently, a modified formulation of the one-group and two-group two-fluid model with interfacial area transport equation was proposed for gas-dispersed condensing flows. Three datasets have been used for validation consisting of condensing two-phase flow data in the unheated section of a vertical annulus with conditions spanning a range of pressures, inlet subcoolings and mass fluxes for benchmarking the various IAC approaches. For bubbly flows, the coupled void transport - IATE simulation results in good agreement in the predictions of the void fraction and the interfacial area concentration under nearly all sixty conditions. Considering the proposed two-group two-fluid IATE model formulation, the group-2 Nusselt number correlation is investigated to account for the appropriate heat transfer length scale for group-2 bubbles. Validation of the proposed two-group two-fluid model against the new dataset shows good agreement with experimental data with significant improvement over the one-group IATE model for conditions with substantial group-2 void fraction throughout the simulation domain.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
NASA NTRS2013

Experimental Investigation of Flow Condensation in Microgravity

Future manned missions to Mars are expected to greatly increase the space vehicle's size, weight, and heat dissipation requirements. An effective means to reducing both size and weight is to replace single-phase thermal management systems with two-phase counterparts that capitalize upon both latent and sensible heat of the coolant rather than sensible heat alone. This shift is expected to yield orders of magnitude enhancements in flow boiling and condensation heat transfer coefficients. A major challenge to this shift is a lack of reliable tools for accurate prediction of two-phase pressure drop and heat transfer coefficient in reduced gravity. Developing such tools will require a sophisticated experimental facility to enable investigators to perform both flow boiling and condensation experiments in microgravity in pursuit of reliable databases. This study will discuss the development of the Flow Boiling and Condensation Experiment (FBCE) for the International Space Station (ISS), which was initiated in 2012 in collaboration between Purdue University and NASA Glenn Research Center. This facility was recently tested in parabolic flight to acquire condensation data for FC-72 in microgravity, aided by high-speed video analysis of interfacial structure of the condensation film. The condensation is achieved by rejecting heat to a counter flow of water, and experiments were performed at different mass velocities of FC-72 and water and different FC-72 inlet qualities. It is shown that the film flow varies from smooth-laminar to wavy-laminar and ultimately turbulent with increasing FC-72 mass velocity. The heat transfer coefficient is highest near the inlet of the condensation tube, where the film is thinnest, and decreases monotonically along the tube, except for high FC-72 mass velocities, where the heat transfer coefficient is enhanced downstream. This enhancement is attributed to both turbulence and increased interfacial waviness. One-ge correlations are shown to predict the average condensation heat transfer coefficient with varying degrees of success, and a recent correlation is identified for its superior predictive capability, evidenced by a mean absolute error of 21.7%.

microgravity↗
DOE OSTI2024

Evaluation and development of flow condensation correlations using the data from low GWP refrigerants in an axial micro-fin aluminum tube

To mitigate global warming, the world is transitioning to refrigerants with low global warming potential (GWP). Supporting this shift requires a model that can accurately predict the heat transfer and pressure drop of new refrigerants, crucial for designing efficient heat exchangers. Existing models, however, are largely based on currently deployed refrigerants and primarily developed for unexpanded micro-fin tubes with spiral angles of 6° to 30°. Their applicability to new refrigerants, especially in expanded micro-fin tubes, is uncertain. This study assesses the performance of four well-known condensation models for six emerging refrigerants—R-32, R-454B, R-454C, R-455A, R-1234yf, and R-1234ze(E)—against experimental data. Initially, the Han and Lee (2005) model shows the best prediction accuracy with a mean absolute deviation (MAD) of 22.1 %. To enhance the accuracy of heat transfer models for new refrigerants and geometries with large temperature glides, two approaches are proposed. Here, the first approach applies a simple correction factor, reducing the MAD of the Cavallini et al. (2009) model from 68.2 % to 15.4 %. The second approach uses the variable metric method for minimization, fitting new constants to the data. This optimization results in the Kedzierski and Goncalves (1997) model achieving the highest accuracy, with a MAD of 13.1 %. For pressure drop models, the Cavallini et al. (1997) model is the most accurate with a MAD of 6.4 %, followed by the Haraguchi et al. (1993) model with a MAD of 9.4 %. Due to its simplicity, the Haraguchi et al. (1993) model is a practical option for predicting frictional pressure drop.

Axial micro-fin tubes↗
NASA NTRS1980

The finite element duct eigenvalue problem - An improved formulation with Hermitian elements and no-flow condensation

Hermitian elements are used in a finite element solution for the eigenvalue problem in lined ducts with flow. These elements give significantly greater accuracy for reduced dimensionality when compared with Lagrangian elements. Spurious mode generation associated with the Lagrangian formulation is eliminated. A dramatic improvement in the ratio of the number of reliable eigenvalues to the total number of computed eigenvalues is effected by the use of a condensation scheme based on the no-flow eigenvectors. Results are presented for two dimensional and axisymmetric ducts. In the axisymmetric case good resolution is obtained even for high order, high frequency modes by the use of continuously graded meshes.

Astley, R. J.↗
NASA NTRS1987

Vapor deposition and condensate flow on combustion turbine blades - Theoretical model to predict/understand some corrosion rate consequences of molten alkali sulfate deposition in the field or laboratory

An analysis is undertaken of aerodynamically- and centrifugally-driven liquid condensate layers on nonisothermal combustion turbines' stator vanes and rotor blades. Attention is given to the quantitative consequences of one possible mechanism for the initiation of 'hot corrosion' in the underlying blade material through a 'fluxing' of the protective oxide coating by the molten salt of the Newtonian condensate film. Illustrative calculations are presented for the condensate streamline pattern and the distributions of the steady-state condensate layer thickness, together with the corresponding oxide dissolution rate, for a test turbine blade.

Rosner, Daniel E.↗
NASA NTRS1974

A photographic study of flow condensation in 1-g and zero-gravity environments

The test articles investigated include two full-scale radiator/condenser panels and a system of three parallel-connected fused quartz tubes. Testing was performed initially on the ground, with both horizontal and inclined flow passage orientations, and additionally in an aircraft flying 0-g trajectories. The photographic observations were made with two high speed cameras and a low speed camera. The flow regimes observed are compared with those predicted by the Baker chart (1954). The Baker chart is well in accord with physical reality in the annular flow region. However, a stratified-annular flow regime observed has no counterpart in the Baker categorization.

Keshock, E. G.↗
DOE OSTI2024

Experimental Study on Flow Condensation of Low Global Warming Potential Refrigerants in a Micro-fin Aluminum Tube

This study investigates the dynamic shifts in refrigerant technologies driven by environmental regulations, particularly emphasizing low global warming potential (GWP). Moreover, there is a rising trend in the adoption of aluminum tubes with internal axial micro-fin structures in heat exchangers to reduce costs. The research focuses on the condensation process within an expanded axial micro-fin aluminum tube with a 5.96 mm fin-tip diameter. Various refrigerants are analyzed, including both single compounds (R-32, R-1234yf, R-1234ze(E)) and zeotropic mixtures (R-454B, R-454C, R-455A). Experimental procedures cover a range of condensation temperatures (35~45 °C), reduced pressures (0.21~0.55), and mass fluxes (150~350 kg/(m² s)), providing crucial data on heat transfer coefficients (HTC) and frictional pressure gradient (FPG). This data is particularly significant for high-glide refrigerants and is instrumental in the design of advanced air conditioning and refrigeration systems aimed at mitigating global warming.

Hu, Yifeng↗
NASA NTRSDate not supplied

Flow Boiling & Condensation Experiment (FBCE): Flow Boiling in Earth Gravity and Onboard the International Space Station

Two phase thermal management systems that capitalize on both latent and sensible heats of the working fluid can yield orders of magnitude enhancements in flow boiling and condensation heat transfer coefficients and reduce size and weight of future space systems. Because the understanding of microgravity influences on two-phase flow and heat transfer is quite limited, there is presently an urgent need for a new experimental microgravity facility to enable investigators to perform long-duration flow boiling and condensation experiments in pursuit of reliable databases. This presentation will discuss results from the Flow Boiling and Condensation Experiment (FBCE), a collaborative effort between Purdue University and NASA Glenn Research Center. Experiments have been performed using the final system with the Flow Boiling Module (FBM) in vertical orientation in Earth gravity (Mission Sequence Tests, MST) and in microgravity onboard the International Space Station (ISS). High-speed-video flow visualization, heat transfer, and critical heat flux (CHF) results from the MST are presented for both subcooled liquid and saturated liquid-vapor inlet conditions. CHF predictions made using the Interfacial Lift-off Model are compared with a consolidated database made by compiling FBM datasets obtained in prior years for different orientations in Earth gravity and on parabolic flights. New explicit correlations for CHF and subcooled flow boiling heat transfer coefficient are developed and shown to be excellent in their predictive accuracies against consolidated experimental databases. Computations are performed for flows in microgravity and horizontal flows in Earth gravity, the results of which show a good predictive accuracy for both void fraction and wall temperature. Finally, similar preliminary results from the recent ISS experiments are presented.

Issam Mudawar↗
NASA NTRSDate not supplied

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↗
NASA NTRS1976

Analysis of nitrogen condensation in an expanding nozzle flow

Condensation of nitrogen flow in an expanding nozzle flow is analyzed using one-dimensional gas dynamic equations and the equations for nucleation and droplet growth. Effects of variations in the Tolman constant and the mass accommodation factor are discussed as well as the effect of foreign nuclei. Comparisons are made with experimental data obtained from a small, contoured nozzle.

Wang, F. C.↗