Flow regimes and mechanistic modeling of critical heat flux under subcooled flow boiling conditions

Thermal performance of heat flux controlled boiling heat exchangers are usually limited by the Critical Heat Flux (CHF) above which the heat transfer degrades quickly, possibly leading to heater overheating and destruction.; In an effort to better understand the phenomena, a literature review of CHF experimental visualizations under subcooled flow boiling conditions was performed and systematically analyzed. Three major types of CHF flow regimes were identified (bubbly, vapor clot and slug flow regime) and a CHF flow regime map was developed, based on a dimensional analysis of the phenomena and available data. It was found that for similar geometric characteristics and pressure, a Weber number (We)/thermodynamic quality (x) map can be used to predict the CHF flow regime.; Based on the experimental observations and the review of the available CHF mechanistic models under subcooled flow boiling conditions, hypothetical CHF mechanisms were selected for each CHF flow regime, all based on a concept of wall dry spot overheating, rewetting prevention and subsequent dry spot spreading. It is postulated that a high local wall superheat occurs locally in a dry area of the heated wall, due to a cyclical event inherent to the considered CHF two-phase flow regime, preventing rewetting (Leidenfrost effect). The selected modeling concept has the potential to span the CHF conditions from highly subcooled bubbly flow to early stage of annular flow.; A numerical model using a two-dimensional transient thermal analysis of the heater undergoing nucleation was developed to mechanistically predict CHF in the case of a bubbly flow regime. In this type of CHF two-phase flow regime, the high local wall superheat occurs underneath a nucleating bubble at the time of bubble departure. The model simulates the spatial and temporal heater temperature variations during nucleation at the wall, accounting for the stochastic nature of the boiling phenomena. The model has also the potential to evaluate the post-DNB heater temperature up to the point of heater melting.; Validation of the proposed model was performed using detailed measured wall boiling parameters near CHF, thereby bypassing most needed constitutive relations. It was found that under limiting nucleation conditions; a peak wall temperature at the time of bubble departure can be reached at CHF preventing wall cooling by quenching. The simulations show that the resulting dry patch can survive the surrounding quenching event, preventing further nucleation and leading to a fast heater temperature increase. For more practical applications, the model was applied at known CHF conditions in simple geometry coupled with one-dimensional and three-dimensional (CFD) codes. It was found that, in the case where CHF occurs under bubbly flow conditions, the local wall superheat underneath nucleating bubbles is predicted to reach the Leidenfrost temperature. However, a better knowledge of statistical variations in wall boiling parameters would be necessary to correctly capture the CHF trends with mass flux (or Weber number). In addition, consideration of relevant parameter influences on the Leidenfrost temperature and consideration of interfacial microphysics at the wall would allow improved simulation of the wall rewetting prevention and subsequent dry patch spreading.