Heat transfer enhanced surfaces for horizontal tube falling film evaporator characterized using laser interferometry

The falling film evaporators are a class of heat exchanger that is widely studied. The research for improving the efficiency is still of prime importance because of its widespread applications in many industries such as desalination, food processing, nuclear energy, refrigeration etc. Our motive in this work is to investigate the potential use of heat and mass transfer enhanced surfaces for horizontal tube falling film evaporator to scale up its effectiveness. Four different tube surfaces viz. bare copper tube, Al2O3 thermal spray coated tube, Al2O3 + TiO2 thermal spray coated tube and open cell copper metal foam wrapped tube were taken for the study. Scanning electron microscope, 3D surface profilometer, contact angle metre and energy-dispersive X-ray spectroscopy were utilized to study the surface texture, surface roughness, wettability and composition, respectively. Out of these four surfaces, a total of eight configurations were realized by varying the coating thickness, surface roughness and porosity. A new prototype of horizontal tube falling film evaporator was designed and fabricated with fully wetted flow. An in house developed novel method based on laser interferometry was utilized for the experimental investigation. This non-invasive technique was capable of measuring falling film thickness and falling film interface temperature simultaneously with unprecedented circumferential span. For the film thickness evaluation, an optical shadow method incorporating Otsu's algorithm with precise interface tracking features was used. Mach–Zehnder Interferometer was employed to visualize the isotherm formation and to quantitatively infer the interface temperature. A 2D CFD study based on VOF model was carried out and found to be in good agreement with experimental as well as theoretical results. Further, the effect of flow rate, feed inlet water and body temperature were explored in detail and analysed statistically.