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Low Heat transfer rate in Immersion Quenching Simulation

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Old   January 20, 2025, 19:22
Question Low Heat transfer rate in Immersion Quenching Simulation
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Dear all,


I have an assignment, where I try to simulate an immersion quenching process of an aluminium slab. My guidelines were according to Srinivasan et al. paper, Numerical Simulation of immersion quench cooling process: Part I, but recreated in OpenFOAM. I selected the chtMultiRegionTwoPhaseEulerFoam solver, as that seems to closely match the model from the paper.


I modified the solidQuenching2D case, but after comparing to the experimental data, I have incredibly low heat transfer rate to the fluid. For example, in real life the cooling process mostly ended in 0.5 second, but in my calculation the surface barely cooled 3˚C. I tried tinkering with the model and physical properties without luck. (Weirdly, when turning on phaseChange in /constant/phaseProperties, the 14˚C water starts to boil on the surface). I also tried increasing the mesh resolution, but the heat transfer didn't change.



If someone would be kind to review my case, I would be deeply greatful!


Kind regards,
Endre



/constant/phaseProperties:
Code:
/*--------------------------------*- C++ -*----------------------------------*\
| =========                 |                                                 |
| \\      /  F ield         | OpenFOAM: The Open Source CFD Toolbox           |
|  \\    /   O peration     | Version:  v2406                                 |
|   \\  /    A nd           | Website:  www.openfoam.com                      |
|    \\/     M anipulation  |                                                 |
\*---------------------------------------------------------------------------*/
FoamFile
{
    version     2.0;
    format      ascii;
    class       dictionary;
    object      phaseProperties;
}
// * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * //

type    thermalPhaseChangeTwoPhaseSystem;

phases (gas liquid);

// phase change in the bulk of the fluid.
phaseChange on;

//populationBalances (bubbles);

gas
{
    type            purePhaseModel;
    diameterModel   isothermal;

    isothermalCoeffs
    {
        d0               5e-3;
        p0              1e5;
    }
    Sc              0.7;

    velocityGroupCoeffs
    {
        populationBalance    bubbles;

        formFactor      0.5235987756;

        sizeGroups
        (
            f0  {d  0.5e-4; value   0    ;}
            f1  {d  1.040e-3; value 0    ;}
            f2  {d  1.640e-3; value 0    ;}
            f3  {d  2.265e-3; value 0    ;}
            f4  {d  2.889e-3; value 0    ;}
            f5  {d  3.512e-3; value 0    ;}
            f6  {d  4.141e-3; value 0    ;}
            f7  {d  4.771e-3; value 1    ;}
            f8  {d  5.402e-3; value 0    ;}
            f9  {d  6.033e-3; value 0    ;}
            f10 {d  6.665e-3; value 0    ;}
            f11 {d  7.297e-3; value 0    ;}
            f12 {d  7.929e-3; value 0    ;}
            f13 {d  8.562e-3; value 0    ;}
            f14 {d  9.194e-3; value 0    ;}
            f15 {d  1.194e-2; value 0    ;}
            f16 {d  2.400e-2; value 0    ;}
            f17 {d  2.700e-2; value 0    ;}
            f18 {d  3.000e-2; value 0    ;}
        );
    }

    residualAlpha   1e-4;
}

liquid
{
    type            purePhaseModel;
    diameterModel   constant;
    constantCoeffs
    {
        d               0.00045;
    }
    Sc              0.7;

    residualAlpha   1e-4;
}

populationBalanceCoeffs
{
    bubbles
    {
        continuousPhase liquid;

        coalescenceModels
        (
            PrinceBlanch
            {
                C1  0.05;
                h0  1e-4;
                hf  1e-8;
                turbulentCollisions     true;
                buoyantCollisions       false;
                laminarShearCollisions  false;
            }
        );

        binaryBreakupModels
        ();

        breakupModels
        (
            LaakkonenAlopaeusAittamaa
            {
                C1      6;// Default: 6;
                C2      0.04;
                C3      0.01;
                daughterSizeDistributionModel uniformBinary;
            }
        );

        driftModels
        (
            phaseChange
            {
                pairNames (gasAndLiquid);
            }

            densityChange{}
        );

        nucleationModels
        (
            wallBoiling
            {
                velocityGroup gas;
            }
        );
    }
}


blending
{

    default
    {
        type            linear;
        minFullyContinuousAlpha.gas 0.7;
        minPartlyContinuousAlpha.gas 0.3;
        minFullyContinuousAlpha.liquid 0.7;
        minPartlyContinuousAlpha.liquid 0.3;
    }

    drag
    {
        type            linear;
        minFullyContinuousAlpha.gas 0.7;
        minPartlyContinuousAlpha.gas 0.3;
        minFullyContinuousAlpha.liquid 0.7;
        minPartlyContinuousAlpha.liquid 0.3;
    }

    heatTransfer
    {
        type            linear;
        minPartlyContinuousAlpha.gas 0;
        minFullyContinuousAlpha.gas 1;
        minPartlyContinuousAlpha.liquid 0;
        minFullyContinuousAlpha.liquid 1;
    }

    massTransfer
    {
        type            linear;
        minPartlyContinuousAlpha.gas 0;
        minFullyContinuousAlpha.gas 1;
        minPartlyContinuousAlpha.liquid 0;
        minFullyContinuousAlpha.liquid 1;
    }
}


surfaceTension
(
    (gas and liquid)
    {
        type            constant;
        sigma           0.07;
    }
);

saturationModel
{
    type function1;

    function csvFile;
    functionCoeffs
    {
        nHeaderLine         1;
        refColumn           0;
        componentColumns    (1);
        separator           ",";
        mergeSeparators     no;
        file                "Tsat_water_1_2bar.csv";
        outOfBounds         clamp;
        interpolationScheme linear;
    };
};

aspectRatio
(
    (gas in liquid)
    {
        type            constant;
        E0              1.0;
    }

    (liquid in gas)
    {
        type            constant;
        E0              1.0;
    }
);


drag
(
    (gas in liquid)
    {
        type            IshiiZuber;
        residualRe      1e-4;

        swarmCorrection
        {
            type        none;
        }
    }

    (liquid in gas)
    {
        type            IshiiZuber;
        residualRe      1e-4;
        swarmCorrection
        {
            type        none;
        }
    }
);

virtualMass
(
    (gas in liquid)
    {
        type            constantCoefficient;
        Cvm             0.5;
    }

    (liquid in gas)
    {
        type            constantCoefficient;
        Cvm             0.5;
    }
);

heatTransfer.gas
(
    (gas in liquid)
    {
        type spherical;
        residualAlpha 1e-3;
    }

    (liquid in gas)
    {
        type RanzMarshall;
        residualAlpha 1e-3;
    }
);

heatTransfer.liquid
(
    (gas in liquid)
    {
        type RanzMarshall;
        residualAlpha 1e-3;
    }

    (liquid in gas)
    {
        type spherical;
        residualAlpha 1e-3;
    }
);

phaseTransfer
();

lift
(
    (gas in liquid)
    {
        type        Tomiyama;
    }
);

wallLubrication
(
    (gas in liquid)
    {
        type            Antal;
        Cw1             -0.01;
        Cw2             0.05;
        Cwc             10.0;
        Cwd             6.8;
        p               1.7;
    }
);

turbulentDispersion
(
    (gas in liquid)
    {
        type                Burns;
        sigma               0.7;
        Ctd                 1.0;
        residualAlpha       1e-3;
    }
);

// Minimum allowable pressure
pMin            10000;


// ************************************************************************* //
Attached Files
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