A novel method for measuring heat flux of boiling water is designed and built to study critical heat flux (CHF) and observe the response of a heat flux sensor when CHF occurs. A high temperature heat flux sensor is embedded in the wall of a pipe to get a direct measurement of the surface heat flux and sensor temperature. By submerging the pipe in water and applying a controlled heat flux to the inside diameter over the area where the sensor is located, boiling is created on the outer surface while measuring the heat flux. The heat flux is gradually increased up to CHF and the heat flux response is observed to determine if the heat flux sensor could sense CHF when it occurred. The heat flux sensor is able to consistently measure the value for CHF, which is approximately 510 kW/m" for this system. It is also observed during the experiments that the heat flux response undergoes an inflection of the heat transfer coefficient at a consistent temperature just before reaching CHF. This observed inflection caused the heat flux response to deviate from its cubic relationship with the temperature and drastically increase for a very small change in temperature. This inflection response can be used as an indication for approaching CHF and can also be used to approximate its value without prior knowledge of when it occurs. / Master of Science

Heavy water moderator surrounding each fuel channel is one of the important safety features in CANDU reactors since it provides an in-situ passive heat sink for the fuel in situations where other engineered means of heat removal from fuel channels have failed. In a critical break LOCA scenario, fuel cooling becomes severely degraded due to rapid flow reduction in the affected flow pass of the heat transport system. This can result in pressure tubes experiencing significant heat-up during early stages of the accident when coolant pressure is still high, thereby causing uniform thermal creep strain (ballooning) of the pressure tube (PT) into contact with its calandria tube (CT). The contact of the hot PT with the CT causes rapid redistribution of stored heat from the PT to CT and a large heat flux spike from the CT to the moderator fluid. For conditions where subcooling of the moderator fluid is low, this heat flux spike can cause dryout of the CT. This can detrimentally affect channel integrity if the CT post-dryout temperature becomes sufficiently high to result in continued thermal creep strain deformation of both the PT and the CT. A comprehensive mechanistic model is developed to predict the critical heat flux (CHF) variations along the downward facing outer surface of calandria tube. The model is based on the hydrodynamic model of \cite{Cheung/Haddad1997} which considers a liquid macrolayer beneath an elongated vapor slug on the heated surface. Local dryout is postulated to occur whenever the fresh liquid supply to the macrolayer is not sufficient to compensate for the liquid depletion within the macrolayer due to boiling on the heating surface. A boundary layer analysis is performed, treating the two phase motion as an external buoyancy driven flow, to determine the liquid supply rate and the local CHF. The model takes into account different types of flow regime or slip ratio. It is applicable for a calandria vessel as well, under a sever accident condition where a thermal creep failure is postulated to occur if sustained CHF is instigated in the surrounding shield tank water. Model shows good agreement with the available experimental CHF data. The model has been modified to take into account the effect of subcooling and has been validated against the empirical correction factors. / Dissertation / Doctor of Philosophy (PhD)

Critical Heat Flux (CHF) is an important safety parameter for the design of nuclear reactors. The most commonly used predictive tool for determination of CHF is a look-up table developed using tube data with an average hydraulic test diameter of 8 mm. There exist in the world today nuclear reactors whose geometry is annular, not tubular, and whose hydraulic diameter is significantly smaller than 8 mm. In addition, any sub-channel thermal hydraulic model of fuel assemblies is annular and not tubular. Comparisons were made between this predictive tool and annular correlations developed from test data. These comparisons showed the look-up table over-predicts the CHF values for annular channels, thus questioning its ability to perform correct safety evaluations. Since no better tool exists to predict CHF for annular geometry, an effort was undertaken to produce one. A database of open literature annular CHF values was created as a basis for this new tool. By compiling information from eighteen sources and requiring that the data be inner wall, unilaterally, uniformly heated with no spacers or heat transfer enhancement devices, a database of 1630 experimental values was produced. After a review of the data in the database, a new look-up table was created. A look-up table provides localized control of the prediction to overcome sparseness of data. Using Shepard's Method as the extrapolation technique, a regular mesh look-up table was produced using four main variables: pressure, quality, mass flux, and hydraulic diameter. The root mean square error of this look-up table was found to be 0.8267. However, by fixing the hydraulic diameter locations to the database values, the root mean square error was further reduced to 0.2816. This look-up table can now predict CHF values for annular channels over a wide range of fluid conditions. / Graduation date: 2001

Critical heat flux (CHF) and post-CHF are two critical phenomena in light water-cooled nuclear power plants regarding safety. Even though the general trends of CHF and post- CHF are known, the exact mechanisms are still unknown. To better understand CHF and post-CHF, experimental flow boiling facilities are constructed around the world. However, these facilities are limited in their experimental conditions and spatial resolution necessary to advance our understanding of two-phase heat transfer. Previous rod surface measurements were collected with thermocouples to measure CHF location and temperature excursion, yet thermocouples provide limited spatial resolution, which leads to significant uncertainties in the CHF prediction. On the other hand, optical fiber temperature sensors can measure the temperature and the CHF propagation with high spatial resolution. Also, the capability of the optical fiber at high temperatures has been proven in previous studies. The current study aims to apply optical fiber at high-pressure and high mass fluxes. The high-Pressure HIgh-temperature annuLUS flow (PHILUS) facility was designed to provide desired working conditions in the test section that uses optical fiber temperature sensors. The PHILUS test section has a length of 1320 mm, with 1000 mm of heated length. The working conditions of the PHILUS are up to 18 MPa, temperatures up to 357◦C, and coolant mass flux from 500 to 3700 kg/m2s. The main components of the loop are a steam separator, two heat exchangers (a condenser and a cooler), a bladder-type accumulator, two bypass lines, and a high-pressure pump. Coolant-Boiling in Rod Arrays-Two Fluids (COBRA-TF) code was used to design the CHF and post-CHF experiments to be performed at the PHILUS facility. / Master of Science / A nuclear power plant produces heat which is transferred from the reactor core through the coolant. The coolant water flows through the reactor core to safely transport the heat that ultimately is used to produce electrical energy. If the balance between the power produced by fission and the energy removed by the coolant is changed, it can lead to potential damage to the reactor core. The maximum heat transfer rate occurs at the point where a vapor blanket covers the surface of the fuel cladding. At this point, known as Critical Heat Flux (CHF), the surface temperature drastically increases. To better understand and better predict the CHF, experimental facilities are needed. Even though there are several facilities worldwide, most of them have limited working conditions and measurement capabilities. Past experiments used thermocouples to measure the surface temperature with a very small spatial resolution, which causes very large uncertainties in the CHF and post-CHF predictions. On the other hand, optical fiber sensors can be used to measure temperature with very high spatial resolution. The high-Pressure HIgh-temperature annuLUS flow (PHILUS) facility was designed in this work to apply optical fibers in the measurement of the rod surface temperature and simulations were performed to show its advantages. The working conditions of the PHILUS are comparable to commercial pressurized water reactors.

Durante um acidente em uma usina nuclear, a integridade do vaso pressurizado deve ser assegurada. Em resposta a um possível derretimento do combustível nuclear, a atual geração de usinas possui um sistema para a injeção de água potável na cavidade do vaso pressurizado com intuito de resfriar sua parede, prevenindo danos a sua estrutura e evitando o vazamento de material radioativo. Esse estudo considerou o uso de água marinha como refrigerante para inundar a cavidade do vaso pressurizado combinado com a fixação de um estrutura porosa em forma de grade em sua parede externa como meio de aprimorar a margem de segurança durante a contenção de acidentes. Experimentos de longa duração para a ebulição em piscina de água marinha artificial foram conduzidos em uma superfície circular de cobre plana com 30 mm de diâmetro. Foi encontrado um fluxo de calor crítico de 1; 6 MW/m2 sob pressão atmosférica. Esse valor é significantemente maior que aquele obtido (1; 0 MW/m2) nas mesmas condições experimentais. Foi verificado que os depósitos de sais marinhos podem aumentar a molhabilidade e a capilaridade da superfície de teste, aprimorando assim o fluxo crítico. Combinando a água marinha e a fixação da estrutura porosa sobre a superfície de teste, verificou-se um melhora no coeficiente de transmissão de calor e no fluxo de calor crítico de até 110 % (2; 1 MW/m2), quando comparado a água destilada na superfície limpa, sem a instalação da estrutura. Após os experimentos, foi identificado que muitos dos poros presentes nas superfícies da estrutura porosa encontravam-se bloqueados devido ao aglutinamento de sais marinhos. Isso levou a conclusão que o aumento no valor do fluxo crítico observado para a água marinha artificial ocorreu devido, principalmente, a separação das fases líquida e gasosa do fluido na região próxima a superfície de teste, efeito proporcionado pela forma de grade da estrutura porosa, e ao aumento da molhabilidade e capilaridade da superfície devido a formação dos depósitos marinhos. / During a severe nuclear power plant accident, the integrity of the reactor pressure vessel must be assured. In response to a possible fuel meltdown, operators of the current generation of nuclear power plants are likely to inject water into the reactor pressure vessel to cool down the reactor vessel wall, preserving its integrity and avoiding leakage of radioactive material. This study considers the use of seawater to flood a reactor pressure vessel combined with the attachment of a honeycomb porous plate (HPP) on the vessel outer wall as a way to improve the safety margins for in-vessel retention of fuel. In long-duration experiments, saturated pool boiling of artificial seawater was performed with an upward-facing plain copper heated surface 30 mm in diameter. The resulting value for critical heat flux (CHF) was 1; 6 MW/m2 at atmospheric pressure, a value significantly higher than the CHF obtained when the working fluid was distilled water (1; 0 MW/m2). It was verified that sea-salt deposits could greatly improve surface wettability and capillarity, enhancing the CHF. The combination of artificial seawater and an HPP attached to the heated surface improved the boiling heat transfer coefficient and increased the CHF up to 110% (2; 1 MW/m2) as compared to distilled water on a bare surface. After the artificial seawater experiments, most of the wall micropores of the HPP were clogged because of sea-salt aggregation on the HPP top and bottom surfaces. Thus, the CHF enhancement observed in this case was attributed mainly to the separation of liquid and vapor phases provided by the HPP channel structure and improvement of surface wettability and capillarity by sea-salt deposition.

Study of liquid film dynamics is of significant importance to the understanding and control of various industrial processes that involve spray cooling (condensation), heating (boiling), coating, cleaning and lubrication. For instance, the critical heat flux (CHF) of boiling heat transfer is one of the key parameters ensuring the efficiency and safety of nuclear power plants under both operational and accident conditions, which occurs as the liquid layers (microlayer and macrolayer) near the heater wall lose their integrity. However, an experimental quantification of thin liquid film dynamics is not straightforward, since the measurement at micro-scale is a challenge, and further complicated by the chaotic nature of boiling process. The object of present study is to develop experimental methods for the diagnosis of liquid film dynamics, and to obtain data for the film instability under various conditions. A dedicated test facility was designed and constructed where micro conductive probes and confocal optical sensors were used to measure the thickness and dynamic characteristics of a thin liquid film on various heater surfaces, while a high speed camera was used to get visual observation. Extensive tests were performed to calibrate and verify the two thickness measuring systems. The micro conductive measuring system was proven to have a high reliability and repeatability with maximum system error less than 5µm, while the optical measuring system is capable of recording the film dynamics with spatial resolution of less than 1 mm. The simultaneous measurement on the same liquid film shows that the two techniques are in a good agreement with respect to accuracy, but the optical sensors have a much higher acquisition rate up to 30 kHz, which are more suitable for rapid process. The confocal optical sensors were therefore employed to measure the dynamic thickness of liquid films (ethanol, hexane and water) evaporating on various horizontal heater surfaces (aluminum, copper, silicon, stainless steel and titanium) to investigate the influences of heat flux, the surface and liquid properties on the film instability and the critical thickness. The critical thickness of water film evaporating on various surfaces was measured in the range of 60-150 mm, increasing with the increased contact angle or increased heat flux (evaporating rate) and also with the decreased thermal conductivity of the heater material. The data suggest the conjugate heat transfer nature of the evaporating liquid film dynamics at higher heat fluxes of interest to boiling and burnout. In the case of hexane on the aged titanium surface with contact angle of ~3o, the liquid film is found resilient to rupture, with film oscillations at relatively large amplitude ensuing as the averaged film thickness decreases below 15 µm. To interpret our experimental findings on liquid film evolution and its critical thickness at rupture, a theoretical analysis is also performed to analyze the dynamics of liquid films evaporating on heater surfaces. While the influences of liquid properties, heat flux, and thermal conductivity of heater surface are captured by the simulation of the lubrication theory, influence of the wettability is considered via a minimum free energy criterion. The thinning processes of the liquid films are generally captured by the simulation of the lubrication theory. For the case with ideally uniform heat flux over the heater surface, the instability of the liquid film occurs at the thickness level of tens micro meters, while for the case of non-uniform heating, the critical thicknesses for the film rupture are closer to  the experimental data but still underestimated by the lubrication theory simulation. By introducing the minimum free energy criterion to considering the influence of surface wettability, the obtained critical thicknesses have a good agreement with the experimental ones for both titanium and copper surfaces, with a maximum deviation less than ±10%. The simulations also explain why the critical thickness on a copper surface is thinner than that on a titanium surface. It is because the good thermal conductivity of copper surface leads to uniform temperature distribution on the heat surface, which is responsible for the resilience of the liquid film to rupture. A silicon wafer with an artificial cavity fabricated by Micro Electronic Mechanical System (MEMS) technology was used as a heater to investigate the dynamics of a single bubble in both a thick and thin liquid layer under low heat flux (<60 kW/m2). The maximum departure diameter of an isolated bubble in a thick liquid film was measured to be 3.2 mm which is well predicted by the Fritz equation. However, in a thin liquid layer with its thickness less than the bubble departure diameter, the bubble was stuck on the heater surface with a dry spot beneath. A threshold thickness of the liquid film which enables the dry spot rewettable was obtained, and its value linearly increases with increasing heat flux. In addition, another test section was designed to achieve a constant liquid film flow on a titanium nano-heater surface which helps to successfully carry boiling in the liquid film from low heat flux until CHF. Again, the confocal optical sensor was employed to measure the dynamics of the liquid film on the heater surface under varied heat flux conditions.  A statistical analysis of the measured thickness signals that emerge in a certain period indicates three distinct liquid film thickness ranges: 0~50 µm as microlayer, 50~500 µm as macrolayer, 500~2500 µm as bulk layer. With increasing heat flux, the bulk layer disappears, and then the macrolayer gradually decreases to ~105 µm, beyond which instability of the liquid film may lose its integrity and CHF occurs. In addition, the high-speed camera was applied to directly visualize and record the bubbles dynamics and liquid film evolution. Dry spots were observed under some bubbles occasionally from 313 kW/m2 until CHF with the maximum occupation fraction within 5%.  A dry spot was rewetted either by liquid receding after the rupture of a bubble or by the liquid spreading from bubbles’ growth in the vicinity. This implies that the bubbles’ behavior (growth and rupture) and their interactions in particular are of paramount importance to the integrity of liquid film under nucleate boiling regime. / QC 20111205 / VR-2005-5729, MSWI

The aim of this study is to design and build a miniature spray cooling system, in which the manufactured and adopted chamber, pump and heat exchanger are smaller than the conventional ones. An experiment was conducted to explore the cooling performance of the spray cooling system after its size has been minimized. In the experiment, copper was used to make the heated surface and different working media, such as DI water, as nanofludics with silver and multi-walled carbon nanotubes powder were sprayed on the heated surface to enhance the heat dissipation efficiency of the system. The experiment in this study was set according to two conditions: transient and steady state, with Weber number as the main parameter, to observe the boiling phenomenon of different working media on heated surface and to record the temperature changes of the heated surface. The results were shown in boiling curve and cooling curve. The ultimate goal of this study was to obtain a better understanding of the cooling performance of the miniature spray cooling system in order to apply it to micro-electronic cooling devices, thereby solving the problem of the sharp increase in heating power per unit area on electronic components.

Spray cooling is a technique for achieving large heat fluxes at low surface temperatures by impinging a liquid in droplet form on a heated surface. Heat is removed by droplets spreading across the surface, thus removing heat by evaporation and by an increase in the convective heat transfer coefficient. The addition of nano-sized particles, like aluminum or copper, to water to create a nanofluid could further enhance the spray cooling process. Nanofluids have been shown to have better thermophysical properties when compared to water, like enhanced thermal conductivity. Although droplet size, velocity, impact angle and the roughness of the heated surface are all factors that determine the amount of heat that can be removed, the dominant driving mechanism for heat dissipation by spray cooling is difficult to determine. In the current study, experiments were conducted to compare the enhancement to heat transfer caused by using alumina nanofluids during spray cooling instead of de-ionized water for the same nozzle pressure and distance from the heated surface. The fluids were sprayed on a heated copper surface at a constant distance of 21 mm. Three mass concentrations, 0.1%, 0.5%, and 1.0%, of alumina nanofluids were compared against water at three pressures, 40psi, 45psi, and 50psi. To ensure the suspension of the aluminum oxide nanoparticles during the experiment, the pH level of the nanofluid was altered. The nanofluids showed an enhancement during the single-phase heat transfer and an increase in the critical heat flux (CHF). The spray cooling heat transfer curve shifted to the right for all concentrations investigated, indicating a delay in two-phase heat transfer. The surface roughness of the copper surface was measured before and after spray cooling as a possible cause for the delay.

Bubble nucleation at subcooled flow boiling condition in a horizontal annular channel with a square cross section by the use of high-speed camera is investigated. The channel represents a scaled-down version of a single rod of CANDU reactor core. The experiments were performed by the use of water at pressures between 1-3 atm, constant heat flux of 0.124 MW/m2, liquid bulk subcooling of 32-1oC and mean flow velocities of 0.3-0.4 m/s. Bubble lift-off diameters were obtained from direct high speed videography. The developed model for the bubble lift-off diameter was obtained by analyzing the forces acting on a bubble. Furthermore, a model for the bubble growth rate constant was suggested. The proposed model was then compared to experimental data and it has shown a good agreement with the experimental data. Additionally, the effects of liquid bulk subcooling, liquid pressure and mean flow velocity on bubble lift-off diameter were investigated.

Bubble nucleation at subcooled flow boiling condition in a horizontal annular channel with a square cross section by the use of high-speed camera is investigated. The channel represents a scaled-down version of a single rod of CANDU reactor core. The experiments were performed by the use of water at pressures between 1-3 atm, constant heat flux of 0.124 MW/m2, liquid bulk subcooling of 32-1oC and mean flow velocities of 0.3-0.4 m/s. Bubble lift-off diameters were obtained from direct high speed videography. The developed model for the bubble lift-off diameter was obtained by analyzing the forces acting on a bubble. Furthermore, a model for the bubble growth rate constant was suggested. The proposed model was then compared to experimental data and it has shown a good agreement with the experimental data. Additionally, the effects of liquid bulk subcooling, liquid pressure and mean flow velocity on bubble lift-off diameter were investigated.