Jtam.dvi JOURNAL OF THEORETICAL AND APPLIED MECHANICS 45, 3, pp. 603-619, Warsaw 2007 TURBULENT HEAT TRANSFER IN THIN LIQUID FILMS AT LOW AND HIGH HEAT FLUXES Dariusz Mikielewicz Gdańsk University of Technology, Faculty of Mechanical Engineering, Poland e-mail: Dariusz.Mikielewicz@pg.gda.pl Jarosław Mikielewicz The Szewalski Institute of Fluid-Flow Machinery PAS, Gdańsk, Poland e-mail: jarekm@imp.gda.pl In the paper presented are considerations of turbulent heat transfer in thin liquid films at low and high heat fluxes. Postulated have been simplemodels of heat transfer for laminar and turbulent liquid films formed by impinging jets and exposed to nucleate boiling, namely under high heat fluxes, as well aswithoutnucleateboiling, at lowheatfluxes, as a simplified case.Turbulen- ce in such case is stronglymodified and difficult to bemodelled. Turbulence model due toPrandtl has been appliedwhere, in the case of high heat fluxes, the mixing length is strongly modified. In the case of high heat fluxes, in- corporated into themodel is a blowing velocity, whichmodels the transverse transport of momentum caused by departing bubbles. Calculated have been the velocity and temperature distributions in the liquid film, which enabled determination of the corresponding heat transfer coefficient and the Nusselt number. Key words: blowing velocity, impinging jet, nucleate boiling Notations cp – specific heat δ – boundary layer thickness h – film thickness λ – thermal conductivity ν – kinematic viscosity ρ – density q – heat flux density qvap – heat flux due to evaporation of film Q – volumetric flow rate T – temperature 604 D. Mikielewicz, J. Mikielewicz τ – shear stress ϑ,w – radial and vertical velocity components r,z – radial and vertical co-ordinates uτ – friction velocity, uτ = √ τw0/ρ Subscripts tr – border between laminar and turbulent sublayers i – interface l – liquid m – mean value w – wall 0 – initial value, nozzle outlet Superscripts + – non-dimensional 1. Introduction Surface cooling bymeans of thin liquid films hasmany practical applications. The demand for effective cooling schemes increases the need for the deve- lopment of appliances incorporating high-heat flux convective heat transfer mechanisms such as change of phase. Apart from the areas, where up to da- te the efficiency of cooling was highly desirable, just to mention metallurgy and nuclear power, there is rapidly developing a new branch of applications inmicroelectronics, where seemingly steady trend of achieving ever larger sca- les of circuit integration is straining the capabilities of existing high-heat flux technologies. In such case there are numerous limiting restrictions such as ava- ilable space, choice of coolant, local environmental conditions and maximum allowable surface temperatures. In relation to the range of plate temperatures wemay face differentmodes of convective heat transfer, namely forced convec- tion, nucleate boiling, transitionboilingorfilmboiling.Liquidfilmevaporation can significantly increase the rate of heat removal from the solid surface and renders this kind of heat transfer very efficient. Heat transfer rates are even greater in the case of nucleate boiling. In the paper considered has been a problem of nucleation in the film formed by impinging jet on a hot plate, as well as a simplified case when nucleate boiling is not present. In case of high heat fluxes, temperature of the plate exceeds the saturation temperature, which causes nucleation of bubbles. Several works can be found,where similar topic is investigated, for example Buyevich and Mankevich (1996), Deb and Yao (1989), Liu andWang (2001), Mikielewicz andMikielewicz (2005), Webb Turbulent heat transfer in thin liquid films... 605 and Ma (1996), Wolf et al. (1994). Despite numerous studies regarding that topic, there is still a lack of complete understandingof the phenomenonaswell as theoretical models, which would enable calculation of hydrodynamics and heat transfer in liquid films produced by impinging liquid jets in the nucleate boiling regime. In the paper the issues of turbulence in modelling of thin films featuring nucleate boiling have been addressed in a greater detail. That issue is by no means simple, since the presence of generated bubbles significantly modifies velocity field and hence the turbulence. The theory known from single phase flows has been applied to the cases where strongmodifications of velocity field are found. Modelling of turbulence in such cases is a very challenging task. Standard models of turbulence are usually perceived as not capable, without seriousmodifications, of revealing the phenomena occuring in the flow. In the paper turbulence is modelled using the Prandtl mixing length model, which resolves the problem quite well. Themodel of the thin liquid film formed as a result of jet impingement, scrutinised in the paper, is a simplemodel of boiling heat transfer within such liquid films just outside the stagnation region. The case with nucleate boiling is regarded as a case where large rates of heat are present. In such amodel considered is a change of film thickness due to inertia forces and friction. The transverse component of bubble velocity, in the study, is regarded as constant and has beenmodelled bymeans of the theory of ”blo- wing”. The case taken into consideration consists of two layers, i.e. laminar sublayer and turbulent core in the bulk of the flow. The model is based on the consecutive solution of the conservation equation ofmass,momentumand energy. The obtained solutions are approximate, but in the analytical form, which enables further qualitative examination of solutions. Thedevelopedmo- del forms an extension of the earlier models by the authors (Mikielewicz and Mikielewicz, 1999, 2001, 2002), where the laminar and turbulent films have been considered and the solutions were obtained by means of the ”thin layer theory”. These cases will also be presented here, derived on the basis of sim- plification of the model featuring the nucleate boiling. In the present work, according to procedures developed for respectivemodels, calculated have been shear stresses, velocity and temperature distributions in the liquid film, which enabledalso determination of theheat transfer coefficient andNusselt number, corresponding to the relevant cases. 2. Governing equations Figure 1 shows a schematic diagram of the case under scrutiny applicable to both cases of high and low heat fluxes respectively. The following non- 606 D. Mikielewicz, J. Mikielewicz dimensional quantities have been introduced into the analysis ϑ+ = ϑ uτ z+ = zuτ ν r+ = ruτ ν δ+ = δuτ ν T+ = T T0 τ+ = τ τw τ+0 = τw τw0 q+ = q qw (2.1) Fig. 1. Schematic diagram of a single phase jet Equations describing the behaviour of non-compressible two-dimensional turbulent liquid films written in the boundary layer approximation in cylin- drical co-ordinates yield (Deb and Yao, 1989; Mikielewicz and Mikielewicz, 2005): — continuity equation ∂(r+ϑ+) ∂r+ =0 (2.2) —momentum equation ϑ+ ∂ϑ+ ∂r+ + w0 uτ ∂ϑ+ ∂z+ = τ+0 ∂τ+ ∂z+ (2.3) — energy equation ∂(ϑ+T+) ∂r+ + w0 uτ ∂T+ ∂z+ = qw ρcpT0uτ ∂q+ ∂z+ (2.4) In the above equations the transverse velocity component, w, is assumed constant, namely w ≈ w0 = const, which corresponds to implementation of the so-called ”blowing velocity”. In the discussed case it models the contribu- tion from nucleate boiling. Value of that velocity can be estimated from the rate of evaporation, i.e. w0 = qvap/hfgρv. The total heat flux consists of two Turbulent heat transfer in thin liquid films... 607 components, namely the heat flux due to convection in the liquid and the heat flux due to evaporation q= ql+ qvap (2.5) The heat flux due to evaporation in considered case is very small compared to the heat flux through liquid, however bubbles significantly distort the velocity profile modifying in such a way the turbulence. In the expression (2.5) the radiative heat flux contribution could also be considered, but in the present study that contribution has been omitted due to the fact that in cases to be studied, there are no significant surface temperatures involved. The momentum and energy equations enable determination of general forms of the shear stress and heat flux distributions in the liquid film τ+ =1+ 1 τ+0 ( z+ ∫ 0 ϑ+ ∂ϑ+ ∂r+ dz++ w0ϑ + uτ ) (2.6) q+ =1+ ρcpT0uτ qw z+ ∫ 0 ∂(ϑ+T+) ∂r+ dz++ w0 uτ (1−T+w ) These distributions are valid both for the laminar and the turbulent flow conditions. The boundary conditions for the considered case yield: z = 0 ⇒ τ+ = τ+0 and q + = 1. The challenge now is in appropriate resolution of the shear stress and heat flux in respective sublayers. In themodelpresentedbelow, thermal-hydraulicanalysis of thephenomena in high heat fluxes case followed by the low heat flux case just outside the stagnation region is presented. 2.1. Hydrodynamics of thin liquid films at high heat fluxes 2.1.1. Developing film The boundary layer in the developing region grows as presented in Fig.1. The analysis below pertains to the case where the boundary layer, δ+, is smaller than the liquid film thickness, h+. Such situation is present within the distance of approximately eight nozzle radii from the stagnation point. In such a case the problem needs to be considered in two zones, in the region of boundary layer and beyond, in the region of undisturbed liquid between the boundary layer border and the film border. As the first approximation the velocity profile for a turbulent boundary layer flow on a flat plate has been assumed ϑ+ = ϑ0 uτ (z+ δ+ ) 1 m (2.7) 608 D. Mikielewicz, J. Mikielewicz Such profile satisfies the conditions of zero velocity at the wall and a value of undisturbed velocity at the border of the boundary layer, ϑ0. Beyond the boundary layer the velocity does not vary and is equal to ϑ0. The flow in the boundary layer will be analysed in two regions, namely in the laminar and turbulent sublayers. In the case of high heat fluxes, the border of the laminar boundary layer is assumed to fall at z+ =11.6. That fact should be properly recognised as bubbles strongly modify the velocity field and still the usual assumptions for the division of boundary layer are acceptable. Substitution of (2.7) into the momentum equation gives a relation describing the shear stress distribution in the laminar sublayer τ+ =1+ 1 τ+0 [ a(r+)(z+) 2 m +1+ w0ϑ0 u2τ (z+ δ+ ) 1 m ] (2.8) where a(r+)=− ϑ20δ − m+2 m (m+2)u2τ dδ+ dr+ Solving (2.8) in the laminar sublayer,where τ+ = dϑ+/dz+,weobtainvelocity distribution in that region, i.e. z+ ¬ 11.6 ϑ+ = z++ ma(r+) 2(m+1) (z+) 2(m+1) m + w0ϑ0 u2τ m(δ+) 1 m m+1 (z+) m+1 m (2.9) In the turbulent sublayer (11.6z+tr. In such a case in the region 0 < z+ < z+tr there exists the laminar flow and in the region 11.6