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Master of Science / Department of Mechanical and Nuclear Engineering / Melanie M. Derby / Oil-water separation is an important process in the petroleum industry. This research investigates the use of surface tension forces to improve current oil-water separation technologies. An understanding of oil-water flows in surface tension driven mini-channels is necessary. This work investigates the effects of mini-channel wall material and tube diameter, along with oil viscosity, on flow regimes and pressure drops in mini-channel oil-water flows. A horizontal closed-loop, adiabatic experimental apparatus was constructed and validated using single-phase water. 2.1-mm and 3.7-mm borosilicate glass, 3.7-mm stainless steel and 4.0-mm Inconel tubes, resulting in Eötvös numbers of 0.2, 0.6 and 0.7 were tested. The experimental data were analyzed and compared using two mineral oils (i.e., Parol 70 and 100) with densities of 840 kg/m³ for both and viscosities of 11.7 and 20.8 mPa-s, respectively. Experiments included a wide range of oil superficial velocities (e.g., 0.28-6.82 m/s for glass, 0.28-2.80 m/s for stainless steel and 0.21-2.89 for Inconel) and water superficial velocities (e.g., 0.07-6.77 for glass, 0.07-4.20 m/s for stainless steel and 0.06-3.86 m/s). Flow regimes were observed and classified as stratified, annular, intermittent, and dispersed flow regimes. Effects of tube diameter were observed. For example, the 2.1-mm glass tube had the smaller range of stratified flows and the larger range of annular and intermittent flows compared to the 3.7-mm glass tube. At the same oil and water superficial velocities and relatively the same flow regime, stainless steel and Inconel always displayed higher pressure drop than the glass tube. However, pressure drops were a strong function of flow regime; lowest pressure drops were found for annular flows and highest pressure drops for dispersed flows. Flow regime maps and pressure drop graphs were created. Overall effects of oil viscosity were modest; however, an increase in oil viscosity enhanced flow stability which affected flow regime transition points.

Submitted by CARLA MARIA GOULART DE MORAES (carlagm) on 2015-06-24T17:27:45Z No. of bitstreams: 1 Hoff_Alexandre.pdf: 2065929 bytes, checksum: 98c0be0d6bc2dd6c614a2379999cb6f6 (MD5) / Made available in DSpace on 2015-06-24T17:27:45Z (GMT). No. of bitstreams: 1 Hoff_Alexandre.pdf: 2065929 bytes, checksum: 98c0be0d6bc2dd6c614a2379999cb6f6 (MD5) Previous issue date: 2013-01-18 / CAPES - Coordenação de Aperfeiçoamento de Pessoal de Nível Superior / PROSUP - Programa de Suporte à Pós-Gradução de Instituições de Ensino Particulares / Este trabalho apresenta o desenvolvimento de uma metodologia experimental para medição de fração de vazio em um escoamento bifásico ar-água, utilizando sensor óptico em um minicanal horizontal de 2,6 mm de diâmetro interno. O sistema de medição consiste de um diodo emissor de luz (LED) de alto brilho, uma resistência dependente de luz (LDR), um circuito amplificador e um circuito para aquisição de dados. Os experimentos são realizados com um tubo de vidro que fica entre o LED e o LDR, no qual passa a mistura ar-água e conforme o padrão de escoamento a luz é atenuada no LDR, que altera sua resistência variando a tensão. Os testes são realizados com vazões volumétricas do líquido de 160, 123 e 63 ml/min e volume de gás de 0,05 e 0,1 ml e os padrões de escoamento testados e observados foram do tipo bolhas, pistonados e golfadas. Nos ensaios são registradas imagens do escoamento, ou dos padrões de bolhas, com uma câmera de alta velocidade e o processamento destas imagens é utilizado para valid ar a técnica do sensor óptico. As áreas das bolhas, em pixels, são comparadas com as áreas das curvas do sinal do sensor óptico e uma boa correlação foi encontrada. Uma curva de calibração do sensor é apresentada para padrão de escoamento tipo bolhas, permitindo encontrar uma relação entre a fração de vazio e a tensão medida pelo sensor. Os resultados obtidos mostraram que a técnica do sensor óptico pode ser usada com bons resultados para a medição de fração de vazio média para um escoamento bifásico ar-água e para a identificação de padrões de escoamento em tubos de diâmetro reduzido. / This work presents the development of an experimental methodology for measuring void fraction in an air-water two-phase flow, using optical sensor in a horizontal mini channel of 2.6 mm internal diameter. The measurement system consists of a light emitting diode (LED) of high brightness, light dependent resistor (LDR), amplifier circuit and data acquisition circuit. The experiments are performed with the air-water flow passing through a glass tube section positioned between the LED and LDR . According to the flow pattern, light is attenuated and impinges on LDR, changing its resistance and thus varying the voltage measured by data acquisition circuit. The tests are conducted with liquid volumetric flow of 160, 123 and 63 ml/min and gas volume of 0.05 and 0.1 ml and flow patterns tested and observed were bubbly and plug. During the tests images of the flow are registered, or the bubbles flow patterns, with a high-speed camera and the processing of these images is used to validate the optical sensor technique. The bubble areas, in pixels, are compared to area under the curve produced from optical sensor signal and a good correlation was found. A calibration curve of the sensor is obtained for bubbly flow pattern, and a correlation between void fraction and the tension is proposed. The results show that the optical sensor technique is adequate for average void fraction measurements in air-water two-phase flow and for flow patterns identification in mini channels.

Les préoccupations relatives à la consommation de l’énergie et notamment des pertes provoquent une demande d’optimisation toujours plus forte des procédés. La recherche de l’efficacité maximale dans les échangeurs de chaleur est d’autant plus forte lorsque ceux-ci ne fonctionnent pas au régime nominal. L’étude présentée dans ce mémoire se concentre sur une problématique de l’efficacité des échangeurs thermiques : la distribution diphasique. Le but de ce travail a été de montrer la faisabilité d’un dispositif améliorant la répartition des deux phases dans un échangeur à mini canaux. La méthode choisie a été l’introduction d’ultrasons par le biais de générateurs placés dans le distributeur produisant une fontaine. Cette technologie présente l’avantage d’être facilement modulable en ne changeant que la tension d’entrée des appareils. Ceci permet donc de pouvoir adapter le dispositif aux différentes conditions opératoires. Des essais expérimentaux ont été réalisés dans différentes conditions, en changeant notamment le débit de chaque phase. La densité de flux massique a été variée de 60 kg.m-2.s-1 à 450 kg.m-2.s-1 et le titre massique de moins de 1% à plus de 23% en entrée de section d’essais. Les comparaisons entre les différents essais se sont faite par la mesure des débits de chaque phase sortant des canaux. L’introduction des ultrasons a également été étudiée en jouant sur le placement et le nombre des générateurs d’ultrasons. Cette technologie s’est alors montré viable car la distribution diphasique est améliorée dans une grande majorité des cas testés. Des phénomènes intéressant ont même été observés, permettant lors d’une prochaine étude, des approches différentes mais complémentaires. / Concerns about energy consumption including thermal losses cause a need in greater optimization of the processes. The goal of the maximum efficiency in heat exchangers is even stronger when they do not work at nominal conditions. The study presented in this paper focuses on the two-phase flow distribution problematic. The aim of this work was to demonstrate the feasibility of a device that can improve the distribution of the two phases in a mini-channel heat exchanger. The method chosen was the introduction of ultrasound through generators placed in the distributor where they can produce an ultrasonic fountain. This technology has the advantage of being easily adjustable by changing the input voltage of the devices. This therefore allows the device to adapt to different operating conditions. Experimental tests have been done under different conditions, in particular by changing the flow rate of each phase. The mass flow density was varied from 60 kg.m-2.s-1 to 450 kg.m-2.s-1 and the mass quality of less than 1% to over 23% at the tests section inlet. Comparisons between different tests were made by measuring flow rates of each phase at the outlet of the channels. The introduction of ultrasound was also studied by varying the placement and number of the generators of ultrasound. This technology has been shown as viable two-phase distribution enhancement in a majority of cases tested. Interesting phenomena were even observed, which allows, for a future study, different but complementary approaches.

The demand for more power and performance from electronic equipment has constantly been growing resulting in an increased amount of heat dissipation from these devices. Thermal management of high-density power control units for hybrid electric vehicles is one such application. Over the last few years, the performance of this power control unit has been improved and size has been reduced to attain higher efficiency and performance causing the heat dissipation as well as heat density to increase significantly. However, the overall cooling system has remained unchanged and only the heat exchanger corresponding to the power control unit (PCU) has been improved. This has allowed the manufacturing costs to go down. Efforts are constantly being made to reduce the PCU size even further and also to reduce manufacturing costs. As a consequence, heat density will go up (~ 200 – 250 W/cm2) and thus, a better high performance cooler/heat exchanger is required that can operate under the existing cooling system design and at the same time, maintain active devices temperature within optimum range (<120 – 125 °C) for higher reliability. The aim of this dissertation was to study the various cooling options based on jet impingement, mini-channel, ribbed mini-channel, phase change material and double sided cooling configurations for application in hybrid electric vehicle and other similar consumer products and perform parametric and optimization study on selected designs. Detailed experimental and computational analysis was performed on different cooling designs to evaluate overall performance. Severe constraints such as choice of coolant, coolant flow-rate, pressure drop, minimum geometrical size and operating temperature were required for the overall design. High performance jet impingement based cooler design with incorporated fin-like structures induced swirl and provided enhanced local heat transfer compared to traditional cooling designs. However, the cooling scheme could manage only 97.4% of the target effectiveness. Tapered/nozzle-shaped jets based designs showed promising results (~40% reduction in overall pressure drop) but were not sufficient to meet the overall operating temperature requirement. Various schemes of mini-channel arrangement, which were based on utilizing conduction and convection heat transfer in a conjugate mode, demonstrated improved performance over that of impingement cooling schemes. Impingement and mini-channel based designs were combined to show high heat transfer rates but at the expense of higher pressure drops (~5 times). As an alternate, mini-channel based coolers with ~1.5 mm size channels having trip strips or ribs were studied to accommodate the design constraints and to enhance local as well as overall heat transfer rates and achieve the target operating temperature. A step by step approach to the development of the heat exchanger is provided with an emphasis on system level design. The computational based optimization methodology is confirmed by a fabricated test bed to evaluate overall performance and compare the predicted results with actual performance. Additionally, one of the impingement based configuration (Swirl-Impingement-Fin) developed during the course of this work was applied to the internal cooling of a turbine blade trailing edge and was shown to enhance the thermal performance by at least a factor of 2 in comparison to the existing pin-fin technology for the conditions studied in this work. / Ph. D.

Cette thèse s’inscrit dans le cadre du projet FUI THERMOFLUIDE-RT impliquant des Grands Groupes (Zodiac DS, Safran Hispano, MBDA), des PME (Atmostat, ADR, ControlSys) et cinq laboratoires (CRIStAL, LML Arts et Métiers Paris Tech, LEGI Grenoble, LMT ENS Cachan, CEA-Liten Grenoble). Le but est d’étudier un nouveau système de refroidissement de l’électronique. La technologie retenue est celle d’une boucle fluide diphasique à pompage mécanique (BFDPM). La thèse traite la modélisation dynamique et la validation expérimentale des composants de la boucle. Ceci permet de prévoir l’efficacité du système à partir de ses paramètres d’entrée, d’analyser les problèmes de régimes transitoires, et de proposer un outil de dimensionnement. La méthodologie bond graph est retenue à cause du caractère multi-physique des composants. D’abord, la problématique de base et le contexte sont présentés. Ceci permet d’introduire la solution retenue, celle des BFDPM. Les objectifs de la thèse sont décrits. Ensuite, une description du banc expérimental développé au cours de cette thèse est proposée. Les trois chapitres suivant sont consacrés à l’étude théorique et expérimentale des équipements de la boucle. Chacun de ces chapitres commence par l’état de l’art sur les travaux de modélisation et les corrélations des coefficients d’échange et des pertes de charge. Une seconde partie décrit les phénomènes et les équations. Une troisième partie est réservée à la validation des modèles. Un dernier chapitre récapitule les travaux de couplage des modèles dynamiques validés séparément. En conclusion, un récapitulatif des contributions est effectué. Des perspectives à court et moyen terme sont proposées / This thesis is part of the collaborative project FUI THERMOFLUIDE-RT involving major groups (Zodiac DS, Safran Hispano, and MBDA), SMEs (Atmostat Alcen, ADR, AER, ControlSys) and five laboratories (CRIStAL Ecole Centrale de Lille, LML Arts et Métiers Paris Tech, LEGI Grenoble, LMT ENS Cachan, CEA-Liten Grenoble). The main purpose is to study a new electronic cooling system. The technology chosen consists of a two-phase fluid loop mechanically pumped (TPLMP). The thesis deals with the dynamic modeling and experimental validation of the cooling components. The developed dynamic model allows to predict the efficiency of the cooling loop, to conduct the study of transitional regimes, and provides an original tool dedicated to design the loop components. The bond graph methodology is adopted because of the multi physics character of the studied components. First, the basic issues and the industrial context are presented. This allows to introduce the chosen solution (TPLMP). The objectives of the thesis are described. Then, a description of the rig test is proposed. The following three chapters are devoted to a theoretical and experimental study of the loop equipment. Each chapter begins with a state of the art on modeling and correlations of the heat exchange coefficients and losses. A second part of the chapter describes phenomena and equations. A third part is dedicated to the experimental validation. A final chapter presents the coupling works of dynamic models validated separately. Finally, a summary of all contributions is made. Prospects for future developments in short and medium term are proposed.

Un modèle semi-analytique permettant de simuler le transfert thermique conjugué dans un mini/macro canal plan soumis à des sources de chaleur surfaciques localisées sur les faces externes et variantes en fonction du temps, a été présenté et vérifié. Plus le diamètre hydraulique du canal est petit, plus la caractérisation expérimentale interne (mesure des températures et des flux) en régime thermique permanent ou transitoire à l'aide des capteurs internes est délicate. Une méthode non-intrusive permettant d'estimer les conditions internes à partir des mesures de température par thermographie infrarouge sur les faces externes et d'un modèle semi-analytique, a été effectuée. Comme le coefficient de transfert convectif forcé classique perd son sens en régime instationnaire, une approche alternative basée sur une fonction de transfert, valable pour un système linaire et invariant dans le temps a été mise en œuvre. Cette fonction peut être calculée analytiquement (uniquement pour une géométrie simple) ou estimée expérimentalement (géométrie complexe). Grâce au caractère intrinsèque de cette fonction de transfert, deux capteurs virtuels ont été conçus : capteur virtuel de température et détecteur d'encrassement permettent respectivement d'estimer les températures internes et de détecter l'encrassement qui peut avoir lieu dans l'échangeur à partir des mesures de températures sur les faces externes / A semi-analytical model allowing to simulate the transient conjugate heat transfer in mini/macro plane channel subject to a heat source(s) localized on the external face(s), was presented and verified. The developed model takes into account advection-diffusion in the fluid and conduction in the solid. As the hydraulic diameter of the channel becomes small, the internal experimental characterization (measurement of temperature and heat flux) using internal sensors become tricky because internal sensors located may compromise the structural integrity of the whole system. A non-intrusive method for estimating the internal conditions from infrared temperature measurements on the external faces using the semi-analytical model was performed. Since the classic convective heat transfer coefficient loses its meaning in transient state, an alternative approach based on a transfer function, valid for Linear Time-Invariant (LTI) systems, was highlighted. This function can be calculated analytically only for a simple geometry. For complex geometries it can be estimated experimentally. Thanks to intrinsic character of this function, two characterization methods were designed. The first to estimate the temperature at a point from a measurement at another point in the system (virtual temperature sensor). The second method concerns the detection of fouling layers that may appear in the heat exchanger from temperature measurements on the external faces

The cooling systems in a gas turbine are especially important as the turbine blades and vanes are exposed to extreme temperatures. The relatively cool air is extracted from the compressors and fed to the turbines to cool the turbine blades. The manufacturing of these blades and channels used to cool is especially complicated using conventional manufacturing techniques. Additive Manufacturing (AM) gives the designer much more freedom to design core components. The AM technique currently explored is the Selective Laser Melting process (SLM). The surface area is exposed to the cooling airflow by using lattice structures which can be manufactured at relative ease using AM. This thesis will provide some insights into using AM parts for the cooling, by analyzing the pressure drop that could be expected from superalloys that are manufactured using AM. The surface roughness is an inherent property of the AM components therefore it would be interesting to analyze a turbulent flow through AM channels (CM247LC and INCONEL 939). The thesis deals with turbulent flows as the airflow used for cooling in the gas turbine is most likely turbulent.  The friction factor (Darcy–Weisbach friction factor) is used to relate the impact of the surface roughness to the pressure drop. The results from the previous experiments are contrasted as the flow in the previous experiments was assumed to be fully developed but in reality, it was not. And the accuracy of the previous results to the actual fully developed flow will shed some light on the feasibility of the flow analysis techniques used in the previous experiments. It is found that the previous experimental results for the CM247LC TPs have good agreement with current experimental results but INCONEL 939 exhibits significant deviation. The possible reasons for the deviations are directly linked to the assumptions made to calculate the minor losses. The Test Pieces (TP) analyzed in this thesis have varying length to diameter (L/D) ratios and the impact of the variation of different L/D ratios is analyzed along with varying pressure ratios. Where the flow resistance increases with an increase in L/D and pressure ratio. The technique to accommodate the compressibility of the airflow is also explored in this thesis. Finally, reasons for the manifestation of anomalies are discussed. The probability of the compressibility effects of the airflow on the anomalies was found to be quite high, and concluding remarks are provided.