1. Introduction
Viscous fluids are crucial components used in various applications. They are used as lubricants, in heat exchangers, etc., generally in cooling and heating facilities at very different scales. They are pivotal for cooling cores of nuclear reactors at the large scale, refrigerators and air conditioners at the medium scale, and electronic devices such as transistors and chips at the micro-scale.
For the optimal design and application of these facilities, the parameter dependencies of viscous fluids have to be taken into account. As most applications deal with heat transfer, it is the temperature dependence that is of specific interest, in particular when dealing with a wide temperature range.
For applications in heat transfer, the following fluid parameters have to be taken into account: Density, viscosity, thermal conductivity, and heat capacity. As an example,
Figure 1 shows the temperature dependency of these parameters for the oil SAE90. This oil is commonly known as motor lubricant. According to the grading of the Society of Automotive Engineers (SAE)m its kinetic viscosity ranges between a minimum of 13.5 cSt, and a maximum of 24 cSt at 100 °C. The relations depicted in
Figure 1 yield a value of 18.4 cSt at 100 °C. The exact mathematical formulations used for the graphs are given below.
It is a common observation that viscosity has the highest variability among the four parameters mentioned. This is clearly visible in the plots in
Figure 1. The viscosity plot clearly shows curvature, while the other parameters deviate marginally from linear relations. The viscosity range may span more than one order of magnitude for relatively moderate temperature intervals.
For common fluids, several functional formulations can be found that describe the effect of temperature
T on the parameters. The dependence is often defined in relation to a reference value
Tref.
may represent any of the mentioned parameters. Equation (1) is valid with
and an empirical constant
γ. In reaction engineering temperature dependencies, the general Arrhenius equation is often preferred:
with activation energy
Ea and Boltzmann constant
kB [
2]. The coefficient
in formula (0) depends on the reference temperature. The viscosity dependence on
T in the Arrhenius-type equations is discussed in detail by Messaâdi et al. [
3] and Ike [
4]. For a rigorous dimensionless description, it is necessary to transform it to a functional formulation that is independent of the choice of a reference point. Pawlowski [
1] showed that the one-parametric set of
functions, defined by
fulfils the latter condition. Using the
functions, the parameter dependency can be expressed as:
The formulations in Equation (4) depend on the constants
. As an example,
Table 1 lists the coefficients for the different parameters for SAE90 oil using the first formula in Equation (4). The first version of the dependency is used for all modeling work reported here.
Variable viscosity effects on convective motions have been studied for different geometrical and physical constellations. There are numerous studies concerning the classical Benard setup, where a sample is heated from below and cooled from above, in pure fluids [
5,
6,
7] and in porous media [
8,
9,
10]. Research work is reported on several other geometries. Hossain and Munir [
11] dealt with a truncated cone structure. Hooman and Gurgenci [
12] were concerned with forced convection in a porous channel with constant heat flux from the boundaries. Soares et al. [
13] studied the flow across a heated cylinder. Malkovski and Magri [
14] examined convection in a fault within a geological system. Almost all of the cited work conducts numerical simulation and has no comparison to measured data. Here we are concerned with a setup that is different from all those previously mentioned.
The main aim is to reconstruct observations from several laboratory experiments in which flow is governed by transient viscous convection. The reconstruction of flow patterns observed in a lab by numerical simulation is apparently a challenge as there are few studies addressing it. The history of attempts to model steady convection patterns in the Hele-Shaw cell of the Elder experiment [
15] illustrates the challenge. The difficulties surely increase if the setting is more complex, for example for more complicated geometries, parameter dependencies, high Rayleigh numbers, forced convection, radiation, etc. In comparison, the here-considered experiment seems unproblematic, dealing with laminar flow in simple geometry. Thus, one would expect that the numerical models simulate the observed behavior easily. The here-reported results demonstrate that even under these circumstances, exact prediction of all experiment variants remains a challenge.
Pawlowski [
1] describes laboratory experiments that are based on thermal convection for which the outcome clearly depends on parameter dependencies. The setup is very simple, as sketched in
Figure 2. A closed cylinder containing the fluid at a constant low temperature
T0 is put into a bath of elevated temperature
T1. During the following phase in which the cylinder heats up, the temperature development within is recorded at two positions on the vertical cylinder axis. After the temperature in the entire cylinder has reached an ambient high temperature, the cylinder is put back into a bath with temperature
T0. During the cooling phase that follows, the temperature at the two observation points is further recorded.
In the described experiments, the two temperature sensors are located on the cylinder axis at equal distances from the top and bottom of the cylinder. In
Figure 2, the sensor positions are indicated by A and B. If heat conduction was the dominant process, both locations would show the same temperature graphs. In all of the experiments, however, convection comes into play, and the recorded temperature time series are quite different.
As convective motions strongly depend on the parameter dependencies on temperature, this has to be considered in the setup of laboratory experiments. The issue is outlined in detail by Pawlowski [
1], describing the setup of an experimental series with the aim to find the optimal fluids for use in heat exchangers. While the cited study describes a theoretical approach, based on dimensional analysis, the aim here is to view the experiments from the modeler’s perspective. Using Computational Fluid Dynamics (CFD), i.e., numerical methods, we reconstruct the laboratory facility, choose the relevant formulations in terms of differential equations, and introduce the parameter dependencies. We examine the outcome of the constructed model and check the sensibility concerning numerical parameters and the temperature range. Finally, we compare the output of the numerical model with the results measured in the laboratory.
4. Comparison with Laboratory Experiments
During the run of the experiments reported by Pawlowski [
1], temperatures were recorded by two sensors. The locations of sensors A and B are indicated in
Figure 1. In the described numerical runs, two ‘probes’ were included to simulate the sensor operation. Here we compare the obtained time-series, as far as it is possible.
The following figures show measured values (data, represented by markers) and numerical results (plotted curves) for the heating and cooling stages of the experiments. In the heating part, the markers and curves start at a low temperature value and end at a higher temperature, and vice versa in the cooling part, where the markers and curves start at a high temperature value and finally reach a lower temperature. Locations A and B are indicated in the legend.
In the report [
1], measured data are depicted in a single figure. Similar to the above-described graphical representation, they are shown for heating and cooling, and for locations A and B. However, they are plotted as graphs. The markers in the figures here represent these graphs. The report [
1] mentions the data as the typical output of the experiments, without providing a scale on the temperature axis. Using the numerical model, we explored various temperature ranges in order to check the match between these given data and the sensibility of the results for the temperature range. For the comparison in the graphs, the data curves were adjusted to fit the temperature range of the numerical model.
Figure 8 depicts a comparison between numerical and experimental results at both observation points, A and B, for the heating and cooling stages as described. The model was run with a low temperature of 22 °C and an elevated temperature of 33.4 °C. Obviously, there is no fit between model results and measured time series. The overall development is obviously correct, but its dynamics are much too slow, in two respects: (1) The transition from an initial phase with an almost constant temperature to a dynamic phase with strong gradients appears too late, with the exception of cooling in point A; (2) the gradients in the dynamic phase are smaller than the ones in the observed data. Moreover, the model cannot reproduce the peculiar behavior of the temperature curve at point B in the cooling experiment. There, a phase with small gradients was observed between phases with stronger gradients.
Numerous experiments with the numerical model were performed to obtain a better fit than the first attempt, shown in
Figure 8, and to investigate the sensitivity to the temperature range. High and low temperatures were changed between 22 °C and 220 °C. In addition, we took into account that there must be a shift in time accounting for the conduction of the container itself to adjust to the changed ambient conditions. We also investigated initial disturbances in the dependent variables. Due to the replacement from one place to another, the cylinder may have been shaken and thus no longer contain the ideal initial values pressure and temperature distribution.
We observed that disturbances in the initial conditions do not have any effect on the results. The disturbances die out so quickly that they are hardly visible in the graphs. Moreover, we find that a shift of 30 s is convenient to obtain better fits with the laboratory data. From the temperature variations, it becomes clear that better fits are obtained for increased temperature ranges.
In all graphs, a partition into three phases can be observed: (1) There is an initial phase with almost constant temperatures; (2) a highly dynamical phase follows; and (3) finally, the temperatures monotonically approach the final state without any noticeable fluctuations.
Figure 9 depicts the results for an increased value of
T1 = 95 °C., in which the phases can be clearly distinguished. The legend indicates whether the graph is obtained from 2D or 3D modeling.
We first discuss the outcome of the simulations in 2D. At point A, the duration of the initial phase is predicted accurately for heating and cooling. At point B, the simulation shows a longer duration in the model than was observed in the laboratory. The dynamics that follow show monotonous graphs for point B in the heating experiment and point A in the cooling experiment. For point A during heating and point B during cooling, the development can be divided in two phases: The first with complex irregular behavior, followed by one with regular behavior. The irregular phase shows steep gradients (at A and B) as well as fluctuations (point B). These irregularities in the curves are surely an effect of local convective flow patterns.
For three of the four curves, the final development of temperature before reaching the new steady state is reproduced well by the results of the simulations. Only the development at point B in the cooling experiment does not match with the laboratory experiments. However, the curve seems to have shifted in time only. The length of the irregular behavior in phase 2 is much longer in the simulation than in the experiment, where a small ’swerve’ (German: Schlenker) was observed.
In addition to the results from a 2D model,
Figure 9 depicts the output from 3D modeling. The rise of
T observed during heating in the lab at position B is reproduced well, while the modeled rise at position A occurs too early. However, the curve does not show disturbances like the one from the 2D simulation. According to this, a phase with high dynamics does not appear.
The falling temperatures during cooling at location A coincide well with the real sensor measurements, while the comparison with the data from sensor B shows a large delay in the model. The curve itself is much smoother than that from the 2D model, indicating that there are not strong dynamics at intermediate times. There is a time period with steeper gradients, followed by smaller gradients—similar to what was observed in the laboratory. Nevertheless, in the model, this swerve appears after 4 and 5 min, while such behavior was observed in the real world in the initial stage for t < 1.5 min.
In order to demonstrate the effect of variable viscosity, a model run with constant viscosity was performed.
Figure 10 shows the results for the same input values and parameter dependencies as those used for the illustrations of
Figure 9. There are minor differences concerning the data for the cooling phase than for the heating phase.
Figure 10 clearly demonstrates the symmetry of the model for constant viscosity. The results of heating and cooling stages can be mirrored on the horizontal axis in the middle of the relevant temperature range. Concerning the behavior of the entire system, the cases of heating and cooling are physically identical if the viscosity is constant.
The curves in
Figure 10 were taken from a model run with constant viscosity, but with all other parameters dependent on temperature as illustrated in
Figure 1. The complete symmetry of the model results depicted in the figure for the heating and cooling stages indicates that the parameter variability of the other parameters, thermal conductivity and heat capacity, is not relevant for the convective motions.
5. Discussion and Conclusions
The influence of parameter dependencies on thermal convection of viscous fluids was simulated by numerical modelling and compared with experimental results. Due to its strong temperature dependency, viscosity was of particular interest. The model output confirmed that the variability of other parameters (except density) is of marginal influence on convection.
The simulations show that the convection in the experimental facility can be divided in three phases: (1) An initial phase with a single eddy that has downward flow along the cylinder axis and upward flow on the walls, or vice versa, depending on heating or cooling; (2) followed by a highly dynamic phase with plumes emerging either at the bottom or the top, with the location depending on heating or cooling; and (3) a smooth development towards the final state with small secondary convective disturbances.
Concerning these phases, the models show minor sensitivity in phases (1) and (3), while the details of the convection patterns in phase (2) depend strongly on the chosen temperature range. While the development observed in the laboratory during phases (1) and (3) is captured well by the model runs, the deviations are highest in the dynamic phase.
The strong dynamics of phase (2) that are present in all 2D CFD simulations were not visible in the experimental results. In fact, during heating, the laboratory sensors recorded a continuous increase in temperatures at all times. For the cooling stage, only a small ’swerve’ (German: Schlenker) is mentioned in the report [
1]. The time of this swerve roughly matches with the dynamic phase of the model output. A comparison of the eddies at the bottom of
Figure 4 and at the top of
Figure 5 for times
t = 1.1 and
t = 1.9 clearly shows the different patterns that lead to the differences in temperature development.
In the final phase, the biggest mismatch between numerical and experimental outputs can be seen during cooling at position B (see
Figure 9). However, a time shift could make the curves match. The mismatch could thus be explained to be an effect of the mentioned difficulties to match the flow details in the preceding dynamic phase. If the model was to progress less dynamically in that phase, the transition to phase (3) would appear earlier. We can conclude that the computer model and laboratory experiment show different behaviors at times when the convective motion is strong.
The general behavior of the measured data, with a relatively smooth change at all times and a slight swerve of the temperature graph measured in the upper part of the facility during cooling, is better reproduced in the 3D simulations, although the timing does not match. As the dynamics in the 3D simulations are closer to the experimental data, we suppose that the strong dynamics seen in the 2D simulation are an artifact of the 2D approach, which in a real-world system is suppressed by the emergence of local 3D eddies.
Numerical modelling of viscous flows has advanced considerably for various situations. In comparison, the main characteristics of this study are (1) rotational geometry, (2) temperature dependency of viscosity, and (3) transient convection. Variations of the model setup, with and without the consideration of inertial effects, coarse and fine meshes, slender and widened boundary layer, modifications of parameter dependencies, etc., show that the results of the models presented here are very robust even concerning the dynamic phase. The stability of the numerical solutions can be seen as a verification of the model.
There are few studies in which numerical results are directly compared with experimental data. Here, a simple documented setup enabled modeling with only a few free parameters. Although the laboratory experiments are documented, some crucial information is not available. The cylinder material and the wall thickness are unknown, so a shift of the time scale due to the fact that the container has to adjust to changed ambient thermal conditions can only be guessed by inspecting the result. There is no comment concerning the variability of the experiment development on the temperature range. The way in which the sensors are fixed within the cylinder, and how the fixation may have influenced the hydraulic and thermal regimes, is not outlined.
For future research, it is recommended that experimental and modelling work should be performed in close cooperation. That enables the modeler to modify the CFD setting in a reasonable way. The experimentalist can modify the experiment, or include further sensors, to check on crucial points for comparison. The here-described experiment design is well suited for checking the effect of viscosity variations on convective motions.