How surface modifications enhance vertical falling film evaporation

Abstract

We use multiphase direct numerical simulations to identify, analyse and quantify components of wall-normal heat flux distributions in evaporative vertical falling films with surface modifications at industrially relevant conditions. Previous experiments showed a potential increase of the heat transfer rate through the film by up to 100 % using various types of modifications. We show that the modifications induce significant advective heat transport and hypothesise that four synergistic mixing mechanisms are behind the heat transfer rate improvement. Additionally, we examine how the important surface topology parameters, pitch $\hat {p}$ (distance between modifications), height $\hat {h}$ and the liquid Prandtl number $\mathit {Pr}_l$ , influence the mode of heat transport and the Nusselt number $\mathit {Nu}$ . We show that $\hat {p}/\hat {h} \approx 10$ maximises $\mathit {Nu}$ and that the optimal pitch is related to the recirculation zone length $L_r$ behind the modification. We find that $L_r/\hat {h} \approx 3.5$ and that $\mathit {Nu} \propto \mathit {Pr}_l^{0.42}$ in the investigated parameter ranges. We also show that all our cases on both smooth and modified surfaces have $\mathit {Pe}_l \gg 1$ and collapse well on a line $\mathit {Nu} \propto (\mathit {Pe}_l/\mathit {Re})^{0.35}$ . This relation suggests that $\mathit {Nu}$ is governed by the balance of film mixing, thermal resistance and diffusivity, and that the ratio $\mathit {Pe}_l/\mathit {Re}$ can be used to estimate $\mathit {Nu}$ . Our methodology and findings extend the knowledge concerning the mechanisms behind the heat transfer improvement due to surface modifications and facilitate guidelines for designing more efficient modified surfaces in industrial evaporators.