Scalable Micro/nanostructured Surfaces for Thin-film Condensation Heat Transfer Enhancement in Steam Power Plants PDF Download
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Author: Yajing Zhao (Mechanical engineer)
Publisher:
ISBN:
Category :
Languages : en
Pages : 0
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Book Description
Steam power plants, which contribute to over 50% of energy production globally, rely on condensers to control system-level energy efficiency. Due to the high surface energy of common heat exchanger materials, the vapor condenses by forming a continuous liquid film with low thermal conductivity (filmwise condensation), hindering heat transfer from the vapor side to the condenser surface. Hydrophobic surfaces achieved by either chemical methods (e.g., coating treatment) or physical methods (e.g. structures design) have shown great promise in enhancing condensation heat transfer by promoting dropwise condensation. However, the short lifetime and high fabrication cost of most of these hydrophobic surfaces remain a challenge for long-term and large-scale industrial applications. A promising solution to enhancing condensation heat transfer in a robust and scalable manner is to control the thickness and thermal conductivity of the condensate film, which we term thin-film condensation. This can be achieved by sandwiching a thin layer of porous metal wick between a hydrophobic membrane and the condenser surface to confine the condensed liquid, forming a thin liquid-metal composite film that significantly improves the effective thermal conductivity of the condensate-filled porous media. In this work, we designed, fabricated, tested, and demonstrated thin-film condensation heat transfer using commercially available materials and scalable approaches. First, we proved the concept using biphilic, microchannel-assisted hierarchical copper surfaces made of commercially available copper foams and copper meshes. Condensation heat transfer on the hierarchical copper surfaces was characterized to be up to 2x as compared to the conventional filmwise condensation, even with flooding on the surface due to the defects on the mesh and the coating. Then, we investigated electrospinning as a potential approach to customize hydrophobic membranes for the thin-film condenser surfaces. The key benefit of the hydrophobic membrane in the surface design is to generate capillary pressure through micro/nanoscale pores, which acts as the driving force for the condensate flow in the metal wick. We conducted a parametric study on the effects of several key fabrication parameters on the pore size of the electrospun membrane, with the help of the fractional factorial design. Solution feeding rate was found to be the most impactful parameter on the membrane pore size and should be considered the most during membrane optimization. A heat and mass transfer model was developed to predict the heat transfer performance of the thin-film condenser surfaces made of electrospun membranes and porous copper wicks. Upon careful design of the surface structures, an over 5x heat transfer enhancement is expected on these thin-film condensers, which is comparable to the state-of-the-art dropwise condensation. Finally, a techno-economic analysis was conducted on the thin-film condensers. The result shows that the additional material for the condenser tube modification costs less than 10% of the condenser cost. However, with the expected 5x steam-side condensation heat transfer performance, thin-film condensers will be able to increase power plants' output by 2-6%, which is equivalent to over $10B of the value proposition for steam power plants across the globe.
Author: Yajing Zhao (Mechanical engineer)
Publisher:
ISBN:
Category :
Languages : en
Pages : 0
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Book Description
Steam power plants, which contribute to over 50% of energy production globally, rely on condensers to control system-level energy efficiency. Due to the high surface energy of common heat exchanger materials, the vapor condenses by forming a continuous liquid film with low thermal conductivity (filmwise condensation), hindering heat transfer from the vapor side to the condenser surface. Hydrophobic surfaces achieved by either chemical methods (e.g., coating treatment) or physical methods (e.g. structures design) have shown great promise in enhancing condensation heat transfer by promoting dropwise condensation. However, the short lifetime and high fabrication cost of most of these hydrophobic surfaces remain a challenge for long-term and large-scale industrial applications. A promising solution to enhancing condensation heat transfer in a robust and scalable manner is to control the thickness and thermal conductivity of the condensate film, which we term thin-film condensation. This can be achieved by sandwiching a thin layer of porous metal wick between a hydrophobic membrane and the condenser surface to confine the condensed liquid, forming a thin liquid-metal composite film that significantly improves the effective thermal conductivity of the condensate-filled porous media. In this work, we designed, fabricated, tested, and demonstrated thin-film condensation heat transfer using commercially available materials and scalable approaches. First, we proved the concept using biphilic, microchannel-assisted hierarchical copper surfaces made of commercially available copper foams and copper meshes. Condensation heat transfer on the hierarchical copper surfaces was characterized to be up to 2x as compared to the conventional filmwise condensation, even with flooding on the surface due to the defects on the mesh and the coating. Then, we investigated electrospinning as a potential approach to customize hydrophobic membranes for the thin-film condenser surfaces. The key benefit of the hydrophobic membrane in the surface design is to generate capillary pressure through micro/nanoscale pores, which acts as the driving force for the condensate flow in the metal wick. We conducted a parametric study on the effects of several key fabrication parameters on the pore size of the electrospun membrane, with the help of the fractional factorial design. Solution feeding rate was found to be the most impactful parameter on the membrane pore size and should be considered the most during membrane optimization. A heat and mass transfer model was developed to predict the heat transfer performance of the thin-film condenser surfaces made of electrospun membranes and porous copper wicks. Upon careful design of the surface structures, an over 5x heat transfer enhancement is expected on these thin-film condensers, which is comparable to the state-of-the-art dropwise condensation. Finally, a techno-economic analysis was conducted on the thin-film condensers. The result shows that the additional material for the condenser tube modification costs less than 10% of the condenser cost. However, with the expected 5x steam-side condensation heat transfer performance, thin-film condensers will be able to increase power plants' output by 2-6%, which is equivalent to over $10B of the value proposition for steam power plants across the globe.
Author: Nenad Miljkovic
Publisher:
ISBN:
Category :
Languages : en
Pages : 185
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Book Description
Micro/nanostructures have long been recognized to have potential for heat transfer enhancement in phase-change processes by achieving extreme wetting properties, which is of great importance in a wide range of applications including thermal management, building environment control, water harvesting, desalination, and industrial power generation. This thesis focuses on the fundamental understanding of water vapor condensation on superhydrophobic surfaces, as well as the demonstration of such surfaces for enhanced condensation heat transfer performance. We first studied droplet-surface interactions during condensation on superhydrophobic surfaces to understand the emergent droplet wetting morphology. We demonstrated the importance of considering local energy barriers to understand the condensed droplet morphologies and showed nucleation-mediated droplet-droplet interactions can overcome these barriers to develop wetting states not predicted by global thermodynamic analysis. To minimize these droplet-droplet interactions and ensure the formation of favorable morphologies for enhanced condensation heat transfer, we show that the structure length scale needs to be minimized while ensuring the local energy barriers satisfy the morphology dependent criteria. This mechanistic understanding offers insight into the role of surface-structure length scale and provides a quantitative basis for designing surfaces optimized for condensation in engineered systems. Using our understanding of emergent droplet wetting morphology, we experimentally and numerically investigated the morphology dependent individual droplet growth rates. By taking advantage of well-controlled functionalized silicon nanopillars, the growth and shedding behavior of both suspended and partially wetting droplets on the same surface during condensation was observed. Environmental scanning electron microscopy was used to demonstrate that initial droplet growth rates of partially wetting droplets were 6 times larger than that of suspended droplets. A droplet growth model was developed to explain the experimental results and showed that partially wetting droplets had 4-6 times higher heat transfer rates than that of suspended droplets. Based on these findings, the overall performance enhancement created by surface nanostructuring was examined in comparison to a flat hydrophobic surface. These nanostructured surfaces had 56% heat flux enhancement for partially wetting droplet morphologies, and 71% heat flux degradation for suspended morphologies in comparison to flat hydrophobic surfaces. This study provides fundamental insights into the previously unidentified role of droplet wetting morphology on growth rate, as well as the need to design nanostructured surfaces with tailored droplet morphologies to achieve enhanced heat and mass transfer during dropwise condensation. To create a unified model for condensation capable of predicting the surface heat transfer for a variety of surface length scales, geometries, and condensation conditions, we incorporated the emergent droplet wetting morphology, individual droplet heat transfer, and size distribution. The model results showed a specific range of characteristic length scales (0.5 - 2 ptm) allowing for the formation of coalescence-induced jumping droplets with a 190% overall surface heat flux enhancement over conventional flat dropwise condensing surfaces. This work provided a unified model for dropwise condensation on micro/nanostructured superhydrophobic surfaces and offered guidelines for the selection of ideal structured surfaces to maximize heat transfer. Using the insights gained from the developed model and optimization, a scalable synthesis technique was developed to produce functionalized oxide nanostructures on copper surfaces capable of sustaining superhydrophobic condensation. Nanostructured copper oxide (CuO) films were formed via chemical oxidation in an alkaline solution resulting in dense arrays of sharp CuO nanostructures with characteristic heights and widths of -1 pm and -300 nm, respectively. Condensation on these surfaces was characterized using optical microscopy and environmental scanning electron microscopy to quantify the distribution of nucleation sites and elucidate the growth behavior of individual droplets with characteristic radii of -1 to 10 pm at supersaturations
Author: Emre Olceroglu
Publisher:
ISBN:
Category : Heat
Languages : en
Pages : 258
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Book Description
Because of their adjustable wetting characteristics, micro/nanostructured surfaces are attractive for the enhancement of phase-change heat transfer where liquid-solid-vapor interactions are important. Condensation, evaporation, and boiling processes are traditionally used in a variety of applications including water harvesting, desalination, industrial power generation, HVAC, and thermal management systems. Although they have been studied by numerous researchers, there is currently a lack of understanding of the underlying mechanisms by which structured surfaces improve heat transfer during phase-change. This PhD dissertation focuses on condensation onto engineered surfaces including fabrication aspect, the physics of phase-change, and the operational limitations of engineered surfaces. While superhydrophobic condensation has been shown to produce high heat transfer rates, several critical issues remain in the field. These include surface manufacturability, heat transfer coefficient measurement limitations at low heat fluxes, failure due to surface flooding at high supersaturations, insufficient modeling of droplet growth rates, and the inherent issues associated with maintenance of non-wetted surface structures. Each of these issues is investigated in this thesis, leading to several contributions to the field of condensation on engineered surfaces. A variety of engineered surfaces have been fabricated and characterized, including nanostructured and hierarchically-structured superhydrophobic surfaces. The Tobacco mosaic virus (TMV) is used here as a biological template for the fabrication of nickel nanostructures, which are subsequently functionalized to achieve superhydrophobicity. This technique is simple and sustainable, and requires no applied heat or external power, thus making it easily extendable to a variety of common heat transfer materials and complex geometries. To measure heat transfer rates during superhydrophobic condensation in the presence of non-condensable gases (NCGs), a novel characterization technique has been developed based on image tracking of droplet growth rates. The full-field dynamic characterization of superhydrophobic surfaces during condensation has been achieved using high-speed microscopy coupled with image-processing algorithms. This method is able to resolve heat fluxes as low as 20 W/m2 and heat transfer coefficients of up to 1000 kW/m2, across an array of 1000's of microscale droplets simultaneously. Nanostructured surfaces with mixed wettability have been used to demonstrate delayed flooding during superhydrophobic condensation. These surfaces have been optimized and characterized using optical and electron microscopy, leading to the observation of self-organizing microscale droplets. The self-organization of small droplets effectively delays the onset of surface flooding, allowing the superhydrophobic surfaces to operate at higher supersaturations. Additionally, hierarchical surfaces have been fabricated and characterized showing enhanced droplet growth rates as compared to existing models. This enhancement has been shown to be derived from the presence of small feeder droplets nucleating within the microscale unit cells of the hierarchical surfaces. Based on the experimental observations, a mechanistic model for growth rates has been developed for superhydrophobic hierarchical surfaces. While superhydrophobic surfaces exhibit high heat transfer rates they are inherently unstable due to the necessity to maintain a non-wetted state in a condensing environment. As an alternative condensation surface, a novel design is introduced here using ambiphilic structures to promote the formation of a thin continuous liquid film across the surface which can still provide the benefits of superhydrophobic condensation. Preliminary results show that the ambiphilic structures restrain the film thickness, thus maintaining a low thermal resistance while simultaneously maximizing the liquid-vapor interface available for condensation.
Author: Jean Hope Sack
Publisher:
ISBN:
Category :
Languages : en
Pages : 58
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Book Description
Increasing worldwide and domestic demands for power and clean water will require advanced heat transfer materials. Superhydrophobic micro- and nano-structured surfaces which promote a jumping droplet mode of condensation have been shown to enhance heat transfer over conventional film wise condensation surfaces, but limited robustness testing has been reported validating feasibility of industrial implementation. This thesis seeks to quantify the robustness of a variety of nanostructures, substrates and coatings by analyzing contact angle measurements and SEM imaging over the course of accelerated robustness testing. This testing was enabled through the design and construction of three custom-built setups intended to accelerate the onset of failure mechanisms. These setups consist of a flow setup to observe resistance to shear flows from internal condensation steam flow, a droplet impingement setup to test mechanical durability, and an elevated temperature condensation chamber to characterize thermal stability. Methods for fabricating nanostructures were also developed, and scalable zinc oxide nanowires (ZnO) and copper oxide nanoblades (CuO) were used. CuO nanoblades were etched into copper, and ZnO nanowires were grown on silicon, low carbon steel, titanium, stainless steel, and electroplated nickel. Hydrophobic coatings tested on these surfaces included stearic acid and two polymer coatings: P2i (40nm) and Semblant. Observed failure mechanisms were coating degradation and poor nanostructure adhesion. Nanostrucure adhesion issues were observed as delamination of ZnO nanowires primarily on stainless steel substrates. Adhesion was improved through the addition of an electroplated nickel layer before nanowire growth, but delamination was still observed. This is likely the result a large mismatch in coefficient of thermal expansion between the ZnO nanowires and the substrate. The etched CuO nanostructures with a fluorinated polymer coating (P2i) showed very little change in performance throughout robustness testing. Characterization methods included contact angle measurements to monitor surface uniformity and durability, and scanning electron microscope (SEM) imaging to observe nanostructure degradation and delamination. Preliminary work was also done to functionalize the inside of tubes and design a dedicated test setup to characterize heat transfer measurements for internal jumping condensation. This setup will allow for extended robustness testing over a range of temperatures, pressures, and geometries, and give baseline heat flux values for comparison with dropwise or filmwise internal condensation. While ZnO nanowires still require additional testing and development, CuO nanoblades are good candidates for internal heat transfer measurements and scaled up robustness testing. Assuming this characterization confirms the expected benefits of jumping condensation from increased droplet removal and nucleation density, this technology has the potential to significantly improve power plant efficiency and output worldwide.
Author: Rong Xiao (Ph. D.)
Publisher:
ISBN:
Category :
Languages : en
Pages : 76
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Book Description
Micro/nanostructures have been extensively studied to amplify the intrinsic wettability of materials to create superhydrophilic or superhydrophobic surfaces. Such extreme wetting properties can influence the heat transfer performance during phase-change which is of great importance in a wide range of applications including thermal management, building environment, water harvesting and power production. In particular, superhydrophilic surfaces have been of interest to achieve thin film evaporation with high heat fluxes. Meanwhile, superhydrophobic surfaces with dropwise condensation promises higher heat transfer coefficients than typical filmwise condensation. My thesis work aims at improving fundamental understanding as well as demonstrating practical enhancements in these two areas. A key challenge to realizing thin film evaporation is the ability to achieve efficient fluid transport using superhydrophilic surfaces. Accordingly, we developed a semi-analytical model based on the balance between capillary pressure and viscous resistance to predict the propagation rates in micropillar arrays with high aspect ratios. Our experimental results showed good agreement with the model, and design guidelines for optimal propagation rates were proposed. For micropillar arrays with low aspect ratio and large spacing between pillars, however, we identified that the microscopic sweeping of the liquid front becomes important. We studied this phenomenon, explained the effect of such microscale dynamics on the overall propagation behavior, and proposed a strategy to account for these dynamics. While these propagation studies provide a means to deliver liquid to high heat flux regions, we investigated a different configuration using nanoporous membrane that decouples capillarity from the viscous resistance to demonstrate the potential heat dissipation capability. With nanoporous membranes with average pore diameters of 150 nm and thicknesses of 50 [mu]m, we achieved interfacial heat fluxes as high as 96 W/cm2 via evaporation with isopropyl alcohol. The effect of membrane thickness was studied to offer designs that promise dissipation of 1000 W/cm 2 . Meanwhile, we developed new metrology to measure transient heat transfer coefficients with a temporal resolution of 0.2 seconds during the evaporation process. Such a technique offers insight into the relationship between liquid morphology and heat transfer behavior. Finally, for enhanced condensation, we demonstrated immersion condensation using a composite surface fabricated by infusing hydrophobic oil into micro/nanostructures with a heterogeneous coating. With this approach, three key attributes to maximize heat transfer coefficient, low departure radii, low contact angle, and high nucleation density, were achieved simultaneously. We specifically elucidated the mechanism for the increase in nucleation density and attribute it to the combined effect of reduced water-oil interfacial energy and local high surface energy sites. As a result, we demonstrated approximately 100% enhancement in heat transfer coefficient over state-of-the-art superhydrophobic surfaces with the presence of non-condensable gases. This thesis presents improved fundamental understanding of wetting, evaporation, and condensation processes on micro/nanostructures as well as practical implementation of these structures for enhanced heat transfer. The insights gained demonstrate the potential of new nanostructure engineering approaches to improve the performance of various thermal management and energy production applications.
Author: Daniel John Preston
Publisher:
ISBN:
Category :
Languages : en
Pages : 76
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Book Description
Condensation is a ubiquitous process often observed in nature and harnessed in many industrial processes such as power generation, desalination, thermal management, and building environmental control. Recent advancements in surface engineering have offered new opportunities to enhance condensation heat transfer by drastically changing the wetting properties of the condenser surface. Specifically, the development of superhydrophobic surfaces has been pursued to enhance condensation heat transfer, where the low droplet surface adhesion and small droplet departure sizes increase the condensation heat transfer coefficient. Specifically, when two or more small (~10-100 [mu]m) droplets coalesce on a superhydrophobic surface, they can spontaneously jump away from the surface due to the reduced droplet-surface adhesion and release of excess surface energy, which has been shown to increase heat transfer by 30 - 40% compared to that observed during gravitational shedding of droplets. While this droplet jumping phenomenon has been studied on a range of surfaces, past work has neglected electrostatic interactions and assumed charge neutrality of the droplets. Here, we show that jumping droplets on a variety of superhydrophobic surfaces, including copper oxide, zinc oxide, and silicon nanopillars, gain a net positive charge that causes them to repel each other mid-flight. The charge is determined experimentally by observing droplet motion in a uniform electric field. The mechanism for the charge accumulation is associated with the formation of the electric double layer at the droplet-coating interface and subsequent charge separation during droplet jumping governed by the fast time scales of droplet coalescence. One application of this charging phenomenon is further enhancement of condensation heat transfer by preventing droplet reversal and return to the condenser surface due to the presence of vapor flow towards the surface, which increases the drag on the jumping droplets. This effect limits the possible heat transfer enhancement because larger droplets form upon droplet return to the surface that impede heat transfer until they can be either removed by jumping again or finally shedding via gravity. By characterizing individual droplet trajectories during condensation on superhydrophobic nanostructured copper oxide surfaces, this vapor flow entrainment is shown to dominate droplet motion for droplets smaller than R ~ 30 [mu]m at moderate heat fluxes (q" > 2 W/cm2 ). Subsequently, electric-field-enhanced (EFE) condensation is demonstrated, whereby an externally applied electric field prevents jumping droplet return due to the positive charge obtained by the droplets upon jumping. As a result, with scalable superhydrophobic CuO surfaces, a 50% higher overall condensation heat transfer coefficient is demonstrated compared to a jumping-droplet surface with no applied field for low supersaturations (
Author: Kuang-Han Chu (Ph. D.)
Publisher:
ISBN:
Category :
Languages : en
Pages : 65
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Book Description
Two-phase microchannel heat sinks are of significant interest for thermal management applications, where the latent heat of vaporization offers an efficient method to dissipate large heat fluxes in a compact device. However, a significant challenge for the implementation of microchannel heat sinks is associated with flow instabilities due to insufficient bubble removal, leading to liquid dry-out which severely limits the heat removal efficiency. To address this challenge, we propose to incorporate micro/nanostructures to stabilize and enhance two-phase microchannel flows. Towards this goal, this thesis focuses on fundamental understanding of micro/nanostructures to manipulate liquid and vapor bubble dynamics, and to improve overall microchannel heat transfer performance. We first investigated the role of micro/nanostructure geometry on liquid transport behavior. We designed and fabricated asymmetric nanostructured surfaces where nanopillars are deflected with angles ranging from 7 -52'. Uni-directional liquid spreading was demonstrated where the liquid propagates in a single preferred direction and pins in all others. Through experiments and modeling, we determined that the spreading characteristic is dependent on the degree of nanostructure asymmetry, height-to-spacing ratio of the nanostructures, and intrinsic contact angle. The theory, based on an energy argument, provides excellent agreement with experimental data. This work shows a promising method to manipulate liquid spreading with structured surfaces, which potentially can also be used to manipulate vapor bubble dynamics. We subsequently investigated the effect of micro/nanostructured surface design on vapor bubble dynamics and pool boiling heat transfer. We fabricated micro-, nano-, and hierarchically-structured surfaces with a wide range of well-defined surface roughness factors and measured the heat transfer characteristics. The maximum critical heat flux (CHF) was ~250 W/cm2 with a roughness factor of~-13.3. We also developed a force-balance based model, which shows excellent agreement with the experiments. The results demonstrate the significant effect of surface roughness at capillary length scales on enhancing CHF. This work is an important step towards demonstrating the promising role of surface design for enhanced two-phase heat transfer. Finally, we investigated the heat transfer performance of microstructured surfaces incorporated in microchannel devices with integrated heaters and temperature sensors. We fabricated silicon micropillars with heights of 25 [mu]m, diameters of 5-10 [mu]m and spacings of 5- 10 [mu]m in microchannels of 500 [mu]m x 500 [mu]m. We characterized the performance of the microchannels with a custom closed loop test setup. This thesis provides improved fundamental understanding of the role of micro/nanostructures on liquid spreading and bubble dynamics as well as the practical implementation of such structures in microchannels for enhanced heat transfer. This work serves as an important step towards realizing high flux two-phase microchannel heat sinks for various thermal management applications.
Author: Phuong Pham
Publisher: BoD – Books on Demand
ISBN: 1789851998
Category : Technology & Engineering
Languages : en
Pages : 295
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Book Description
Surface sciences elucidate the physical and chemical aspects of the surfaces and interfaces of materials. Of great interest in this field are nanomaterials, which have recently experienced breakthroughs in synthesis and application. As such, this book presents some recent representative achievements in the field of surface science, including synthesis techniques, surface modifications, nanoparticle-based smart coatings, wettability of different surfaces, physics/chemistry characterizations, and growth kinetics of thin films. In addition, the book illustrates some of the important applications related to silicon, CVD graphene, graphene oxide, transition metal dichalcogenides, carbon nanotubes, carbon nanoparticles, transparent conducting oxide, and metal oxides.
Author:
Publisher: Springer
ISBN: 9783319266947
Category : Science
Languages : en
Pages : 0
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Book Description
This Handbook provides researchers, faculty, design engineers in industrial R&D, and practicing engineers in the field concise treatments of advanced and more-recently established topics in thermal science and engineering, with an important emphasis on micro- and nanosystems, not covered in earlier references on applied thermal science, heat transfer or relevant aspects of mechanical/chemical engineering. Major sections address new developments in heat transfer, transport phenomena, single- and multiphase flows with energy transfer, thermal-bioengineering, thermal radiation, combined mode heat transfer, coupled heat and mass transfer, and energy systems. Energy transport at the macro-scale and micro/nano-scales is also included. The internationally recognized team of authors adopt a consistent and systematic approach and writing style, including ample cross reference among topics, offering readers a user-friendly knowledgebase greater than the sum of its parts, perfect for frequent consultation. The Handbook of Thermal Science and Engineering is ideal for academic and professional readers in the traditional and emerging areas of mechanical engineering, chemical engineering, aerospace engineering, bioengineering, electronics fabrication, energy, and manufacturing concerned with the influence thermal phenomena.
Author: Chuang Wen
Publisher: Springer Nature
ISBN: 9813347651
Category : Science
Languages : en
Pages : 914
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Book Description
This book gathers selected papers from the 16th UK Heat Transfer Conference (UKHTC2019), which is organised every two years under the aegis of the UK National Heat Transfer Committee. It is the premier forum in the UK for the local and international heat transfer community to meet, disseminate ongoing work, and discuss the latest advances in the heat transfer field. Given the range of topics discussed, these proceedings offer a valuable asset for engineering researchers and postgraduate students alike.
