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Vapor shearing is a common issue encountered in the operations of falling film heat exchangers. The vapor stream effect depends on its orientation. This study investigates liquid film hydrodynamics and heat transfer performance under the influence of vapor streams from different orientations. The results indicate that both orientation and velocity of vapor determine the encountering time and position of the films on the tube's two sides. The liquid film thickness uniformity and the liquid column deflection vary significantly depending on the orientation and velocity of the vapor. Zones of accelerated liquid film, climbing liquid film, liquid stagnation, and transition of liquid film flow pattern are observed. The gradient of film thickness along the tube axis and the deflection in time-averaged peripheral film thickness increase as the vapor orientation varies from 0° to 90° and subsequently decrease as the vapor orientation varies from 90° to 180°. Vapor streams have more pronounced effects on time-averaged peripheral film thickness in regions close to the liquid inlet and outlet. Vapor streams result in changes in peripheral heat transfer coefficients toward the downstream side depending on the orientation and velocity of the vapor. The impact of vapor streams on the overall heat transfer coefficient does not directly correlate with the velocity of the vapor when maintaining the same orientation. [ABSTRACT FROM AUTHOR]

Two-phase flow patterns are critical in falling film heat devices. Hydrodynamic characteristics of turbulent falling films across a horizontal triangular tube bundle were studied under a range of film Reynolds numbers and contact angles. A flow pattern map based on the k-means clustering approach was proposed after the intercolumn two-phase flow patterns were grouped. The results demonstrated that that the intercolumn liquid-vapor flow patterns in a horizontal tube bundle could be effectively and reasonably grouped using the k-means clustering approach according to the results of the void fraction and interface area. There are four intercolumn liquid-vapor flow patterns that were identified: bubbles flow, annular-slug-column flow, half-annular flow, and multi-bridges flow. The annular-slug-column flow pattern and the multi-bridges flow pattern are next to one another in the flow pattern map and are capable of transitioning one into the other. It is only through the two transitional flow patterns that the half-annular-column flow pattern and bubbles flow pattern can turn to one another. In the bubbles' flow pattern and half-annular-column flow pattern, respectively, the highest and least averaged heat transfer coefficients are attained. Simply raising the film Reynolds number or lowering the contact angle will not produce the best heat transfer results. [ABSTRACT FROM AUTHOR]

Falling film flow and heat transfer are extensively encountered in various industries of renewable and sustainable energy due to the outstanding heat transfer performance. The predictions in falling film hydrodynamics and heat transfer are crucial for the optimal design of falling film heat exchangers, and there have been considerable advancements made in this area over the past few decades. Considering the gaps in current literature predictions, this paper aims to present a comprehensive review on the correlations of flow pattern transition, film thickness, heat transfer, and liquid film rupture within falling film flowing over horizontal tubes and tube bundles. Through comparisons and summarizations, it can be found that the documented correlations appear to be significantly out of alignment with one another, which greatly restricts the applicability of these predictions. The correlations of falling film thickness that are obtained using regression approach based on dimensional analysis may take into account more factors than the ones modified from Nusselt theory. The predictions of flow pattern transition of falling liquid film with horizontal column are often described as the functions of the film Reynolds number, derived from the Kapitza number or the Galileo number. The functions of Nusselt number, film Reynolds number, Prandtl number, and Archimedes number are typically used to represent sensible and evaporative heat transfer correlations, whereas boiling heat transfer correlations also take into account the influence of heat flux, such as Boiling number. The full process of actual heat transfer is taken into account from both the standpoints of sensible convection and nucleate boiling using the combination functions of various heat transfer forms. Within the ranges of their own parameters, the well-established heat transfer models often offer good accuracy. While the predictions of phase change heat transfer often behave worse, the predictions of sensible heat transfer are more general and accurate. Generally speaking, the minimum film flow rate or the maximum heat flux were the functions that correlated with the inceptions of liquid film rupture. • Provides a comprehensive review of predictions for falling film hydrodynamics and heat transfer. • Describes in fully the most recent advancements in the relevant correlations. • Reviews respectively heat transfer prediction of sensible convection, evaporation, and boiling. • Provides an entire review of falling film heat transfer from subcooled convection to film dryout. • Proposed some recommendations and improvements for future research. [ABSTRACT FROM AUTHOR]

Falling film technology has been widely applied in various industrial processes, but vapor shearing effects cause significant problems. The mechanism by which vapor affects the hydrodynamics of a falling film has not yet been fully understood, particularly for cross vapor streams. In this paper, a three-dimensional model is developed to investigate the hydrodynamics of a falling film on a horizontal tube with a cross vapor stream. The results indicate that (1) there are valley and peak zones during the spreading of the liquid film; (2) the effect of cross vapor flow on the hydrodynamics of the falling film depends on the film flow rate, the cross vapor velocity, and the position on the tube; (3) with increasing vapor velocity, the peripheral film thickness increases on both the upwind and downwind sides for values of z* (the dimensionless axial coordinate) from 0 to 0.1, while decreasing on the upwind side but increasing on the downwind side for values of z* from 0.2 to 0.5; and (4) under the action of the cross vapor stream, liquid film offset occurs, characterized by the formation of new stagnation and detachment zones on the downwind side of the tube. [ABSTRACT FROM AUTHOR]

• Numerical study on falling film flow and heat transfer on porous tubes. • Compared falling film flow and heat transfer on plain and porous tubes. • Studied porosity, layer thickness, and material effects on flow and heat transfer. • Porous layer leads lower flow, thinner film, fewer rupture, better heat transfer. • Smaller porosity, thicker layer, aluminum and copper facilitate heat transfer. Porous surfaces often exhibit exceptional performance in liquid spreading and heat transfer, making them promising candidates for enhancing falling film heat transfer on solid surfaces. This paper delves into the flow and heat transfer characteristics occurring within falling films on horizontal tubes coated with a porous layer. To achieve this, a three-dimensional numerical model that couples the Volume of Fluid (VOF) method with porous media considerations was employed. The investigation comprehensively covers film spreading behavior, flow patterns, film velocity, film thickness, temperature distribution, and heat transfer coefficients, for both plain and porous tubes. Furthermore, we delve into the effects of key parameters, such as porosity, layer thickness, and material properties, on the overall heat transfer process. The results demonstrate the accuracy of our model in reproducing film thickness and heat transfer coefficients within falling films on horizontal porous tubes. When comparing plain tubes to porous ones, some key differences emerge. Specifically, the liquid film on porous tubes spreads more slowly, leading to increased film thickness and fewer occurrences of dry patches. Additionally, porous tubes result in lower film velocity and a more uniform temperature field compared to plain tubes. Interestingly, the findings reveal that smaller porosities yield thicker films and higher heat transfer coefficients, particularly when the porosity is below 0.4. Moreover, thicker porous layers result in thinner films, higher wetting ratios, and increased heat transfer coefficients. Among the materials we tested, aluminum and copper porous layers exhibit the highest heat transfer performance, while steel demonstrates the lowest. [ABSTRACT FROM AUTHOR]

The peripheral heat transfer correlation of the subcooled falling liquid film outside the horizontal tube was established using the present numerical data under different liquid flow rates, heat fluxes, tube sizes, distributor heights, and liquid temperatures. The results indicated that the present correlation can predicate 93% of 2654 data within ±25% in θ = 2°–15°, 92% of 2254 data within ±15% in θ = 15°–165°, and 80% of 1442 data within ±30% in θ = 165°–178°. The peripheral heat transfer correlation can predict 74% of 903 data and 80% of 700 data, respectively, within 0°–180° and 15°–165° with the deviations of ±30%. The sensitivity analysis indicated that the parameter angle and the distributor height have the most and least significant impact on the peripheral heat transfer correlation, respectively. [ABSTRACT FROM AUTHOR]

• Thoroughly studied the variables affecting falling film dehumidification on corrugated plates. • Provided the optimum shape of the corrugated plate for falling film dehumidification performance. • Proposed a mass transfer correlation based on the current numerical data. • Clarified the enhancement mechanism of the corrugated surface for falling film dehumidification. Due to a number of benefits, liquid desiccant dehumidification has received a lot of attention lately. In comparison to previous improvement strategies, corrugated plates have demonstrated higher efficacy in liquid desiccant dehumidification. This study employs computational fluid dynamics to examine the dehumidification performance of falling film liquid desiccant dehumidification on over sinusoidally shaped corrugated plates. The effects of plate geometries, solution parameters, and moist air (concentration of humidity, temperature, and flow rate) were discussed. Additionally, a mass transfer correlation was proposed based on the current numerical data. It is indicated that the corrugated plate significantly enhances dehumidification performance due to the liquid film waves intensification, mass transfer area expansion, and induction of vortexes close to the gas-liquid interface. The most effective falling film dehumidification is achieved using a corrugated plate with a wavelength of 5.0 mm and an amplitude of 0.5 mm. By raising the solution or air inlet temperature, the dehumidification rate is reduced while being strengthened by raising the solution or air inlet concentration, velocity, or air humidity. While decreasing when solution intake concentration or air velocity rises, the efficacy of dehumidification rises as solution velocity does. The proposed mass transfer correlation accurately predicts 93.3 % of the 45 data, with an error of 11 % or less. In the current parameter scopes, the magnitude has a more significant effect on Sh air than the wavelength. Adjustments to air velocity and solution concentration can cause significant fluctuations in Sh air , while air and solution temperature have little effect on Sh air. [ABSTRACT FROM AUTHOR]

• Tested cross vapor effect on the falling film evaporation of low pressure refrigerant. • Conducted larger vapor velocity effect on falling film evaporation in tube bundle. • Compared the cross vapor effect on falling film evaporation of R123 and R134a. • Visualized the cross vapor effect on falling liquid film flow and heat transfer. The falling film evaporation and the effect of cross vapor stream in falling film evaporator with triangular tube bundle using R123 was experimentally investigated. The variations of local and bundle average heat transfer coefficients were described. The tube bundle consisted of 4 × 3 (column × row) of triangular horizontal copper tubes. The tests without vapor effect were conducted with nominal heat fluxes of 20 to 60 kWm–2, saturation temperatures of 6 to 16 °C and film flow rates of 0.016 to 0.18 kgm–1s–1. Cross vapor stream effect experiments were operated at three heat fluxes of 20, 30 and 40 kWm–2 and two film flow rates of 0.035 and 0.07 kgm−1s−1, and the vapor velocity at the narrowest interstice in the tube bundle varies from 0 to 5.0 ms−1. It is indicated that the heat transfer is seriously influenced by the bundle effect while less affected by changing of saturation temperature. With the increase in vapor velocity, the heat transfer performance is generally weakened; the cross vapor stream has a strong influence on falling film evaporation of R123. [ABSTRACT FROM AUTHOR]

Falling film evaporation is an efficient heat transfer mode in refrigeration and air conditioning industries. In this paper, the falling film evaporation performances of R134a and R123 outside four enhanced tubes and a smooth tube are tested. The results reveal that: with the decrease of film flow rate the falling film heat transfer coefficients of both R134a and R123 on the five tubes exhibit two general stages (a plateau stage and a sharp drop stage); for R134a the plateau is quite uniform while for R123 a mild decrease occurs with the decrease in film flow rate. The four enhanced tubes behave differently in heat transfer performances for R134a and R123. R134a provides around 2–3 times of heat transfer coefficients of R123 for all tubes. [ABSTRACT FROM AUTHOR]

• Studied numerically the falling film flow and heat transfer under turbulent regime. • Clarified the dominant factors tube bundle effect in the turbulent condition. • Compared fluid flow and heat transfer results between laminar and turbulent regimes. • Recommended the key parameters and factors for a higher heat transfer performance. Turbulent falling films are commonly encountered in the practical operations of most falling film applications, but the relevant numerical study is very scarce. The hydrodynamics and thermal performance of falling films in horizontal tube bundles under the turbulent regime were numerically investigated in this study. The calculation ranges are: film Reynolds number from 3505 to 8034, heat flux of 47.3 kWm−2, inlet liquid temperature of 46 °C, tube diameter of 19.0 mm and liquid distributor height of 6.4 mm. Based on the results of the present numerical model, the Standard k - ω model is more suitable in reproducing the falling film heat transfer profile, as the present numerical model accurately predicted the turbulent falling film heat transfer characteristics. There are various hydrodynamics depending on the bundle arrangement and flow regime, including splashing, bridging, gas entrainment, Coanda effect, and liquid film thickness. The triangular bundle provides the highest heat transfer coefficient, but the square bundle provides the poorest one, and the square and rotated-triangular tube bundles behave the largest and smallest bundle effect, respectively. The bundle effect is generally independent of film Reynolds number, liquid feeder height and tube spacing. [ABSTRACT FROM AUTHOR]

• Examined surface tension model effect on falling film flow on a horizontal tube. • Surface tension is indispensable in calculation of gravity-driven liquid film flow. • Given microscopic insights of falling film flow for different surface tension models. • Both CSF and CSS models can reliably reproduce the falling liquid film hydrodynamics. Computational fluid dynamics (CFD) modelling is extensively and successfully used for the reproduction of liquid film hydrodynamics. Surface tension significantly influences the numerical reproduction of falling liquid film flow. In this study, the hydrodynamics of the liquid film flow over a horizontal tube and a vertical plate is explored with different surface tension models. The results reveal that the neglect of surface tension leads to quantitative and qualitative distortions in the numerical simulation of the thin liquid film. Both continuum surface force (CSF) and continuum surface stress (CSS) models can produce the hydrodynamic behaviors of the falling film on the horizontal tube and the vertical plate, including pendant droplets, column necking or necking break, thickness of the film, vortex, liquid film detachment, as well as the values and trends of the velocity components. However, the CSF and CSS models produce different transient phase contours and streamlines, as well as different profiles of the time-averaged velocity components of the falling films on the horizontal tube and the vertical plate. Besides, there is no obvious difference between CSF and CSS in the perspective of time-averaged film thickness on a horizontal tube. [ABSTRACT FROM AUTHOR]

Falling film heat and mass transfer, representatives of advanced and low-carbon heat and mass transfer technologies, has been applied in a variety of thermal processes due to its great prospect for heat and mass transfer enhancement. However, the hydrodynamics, heat and mass transfer are significantly influenced by the gas (vapor or air) streams during the operation of falling film heat exchangers. To acquire the detailed profiles of flow, temperature and concentration and to explore the influence mechanism of gas stream shearing on the falling film hydrodynamics and heat and mass transfer, researchers have adopted experimental, analytical and numerical methods for different attempts. This paper presents a comprehensive summarization of the relevant work concerning the hydrodynamic, heat and mass transfer characteristics of falling film components, including the evaporator, absorber, evaporative cooler and dehumidifier. Considering the specific applications, the cocurrent, countercurrent, and cross gas streams shearing on the liquid film on a horizontal tube and bundle, a vertical tube and a vertical plate are reviewed. The objective of this review is to cover sufficient knowledge of the results, findings and insights of gas stream impacts on the hydrodynamics, heat and mass transfer in building utilized heat exchangers to provide guidance on how to maximize the positive effect or at least minimize the negative impact of gas shearing on the falling film heat and mass transfer. Schematics of gas stream models encountered in various applications. [Display omitted] • Provide the first review of the gas stream effect on falling liquid film flow. • Clarified mechanisms of gas effect on liquid film flow, heat and mass transfer. • Summarized studies of gas stream effect on falling film flow, heat and mass transfer. • Concerned film thickness, heat and mass transfer prediction under gas shearing. • Proposed some recommendations and improvements for future research. [ABSTRACT FROM AUTHOR]