Beyond direction-agnostic assumptions: Direction-integrated models for asymmetric falling film thickness and heat transfer under multidirectional vapor shear

Abstract

The orientation of vapor streams in falling film evaporators (FFEs), determined by tube bundle configurations, plays a critical role in shaping liquid film hydrodynamics and heat transfer performance. Conventional models adopt direction-agnostic assumptions, averaging vapor shear effects and introducing significant errors in localized predictions. This study proposes a direction-integrated framework that explicitly incorporates vapor orientation as a governing parameter, capturing the asymmetric effects of multidirectional vapor shear on film thickness and heat transfer. The proposed correlations are validated against a broad range of benchmark data, achieving 80 % of film thickness predictions within ±25 % error, over 86 % of local heat transfer coefficients within ±20 %, and all average values within ±5 %. Comparative analysis shows strong agreement with experimental and numerical results under gravity-driven, laminar conditions. Vapor directionality is shown to significantly alter heat transfer along the tube periphery, especially between upper and lower regions. These findings enhance the predictive reliability of FFE modelling and provide valuable guidance for optimizing evaporator design and improving energy efficiency in industrial applications.