Drying in porous media with gravity-stabilized fronts: experimental results

Analysis of Drying Front Propagation and Coupled Heat and Mass Transfer During Evaporation From Additively Manufactured Porous Structures Under a Solar Flux

Drying front propagation and coupled heat and mass transfer analysis from porous media is critical for soil-water dynamics, electronics cooling, and evaporative drying. In this study, de-ionized water was evaporated from three 3D printed porous structures (with 0.41 mm, 0.41 mm, and 0.16 mm effective radii, respectively) created out of acrylonitrile butadiene styrene (ABS) plastic using stereolithography technology. The structures were immersed in water until all the pores were invaded and then placed on the top of a sensitive scale to record evaporative mass loss. A 1000 W/m2 heat flux was applied with a solar simulator to the top of each structure to accelerate evaporation. The evaporative mass losses were recorded at 15 min time intervals and plotted against time to compare evaporation rates from the three structures. The evaporation phenomena were captured with a high-speed camera from the side of the structures to observe the drying front propagation during evaporation, and a high-resolution thermal camera was used to capture images to visualize the thermal gradients during evaporation. The 3D-structure with the smallest effective pore radius (i.e., 0.16 mm) experienced the sharpest decrease in the mass loss as the water evaporated from 0.8 g to 0.1 g within 180 min. The designed pore structures influenced hydraulic linkages, and therefore, evaporation processes. A coupled heat-and-mass-transfer model modeled constant rate evaporation, and the falling rate period was modeled through the normalized evaporation rate.

Coupling between internal and external mass transfer during stage-1 evaporation in capillary porous media: Interfacial resistance approach

The coupling boundary condition to be imposed at the evaporative surface of a porous medium is studied from pore network simulations considering the capillary regime. This paper highlights the formation of a thin edge effect region of smaller saturation along the evaporative surface. It is shown that this thin region forms in the breakthrough period at the very beginning of the drying process. The size of this region is studied and shown to be not network size dependent. This region is shown to be the locus of a nonlocal equilibrium effect. The features lead to the consideration of a coupling boundary condition involving an interfacial mass transfer resistance and an external mass transfer resistance. Contrary to previous considerations, it is shown that both resistances depend on the variation of the saturation, i.e., the fluid topology, and the size of the external mass transfer layer, i.e., the mass transfer rate. This is explained by the evolution of the vapor partial pressure distribution at the surface which becomes increasingly heterogeneous during evaporation and depends on both the evolving fluid distribution in the interfacial region and the mass transfer rate. However, the geometric effects due to the configuration of the fluids can be separated from rate effects that arise due to the nonequilibrium mass transport.

Lattice Boltzmann Modeling of Drying of Porous Media Considering Contact Angle Hysteresis

Drying of porous media is governed by a combination of evaporation and movement of the liquid phase within the porous structure. Contact angle hysteresis induced by surface roughness is shown to influence multi-phase flows, such as contact line motion of droplet, phase distribution during drainage and coffee ring formed after droplet drying in constant contact radius mode. However, the influence of contact angle hysteresis on liquid drying in porous media is still an unanswered question. Lattice Boltzmann model (LBM) is an advanced numerical approach increasingly used to study phase change problems including drying. In this paper, based on a geometric formulation scheme to prescribe contact angle, we implement a contact angle hysteresis model within the framework of a two-phase pseudopotential LBM. The capability and accuracy of prescribing and automatically measuring contact angles over a large range are tested and validated by simulating droplets sitting on flat and curved surfaces. Afterward, the proposed contact angle hysteresis model is validated by modeling droplet drying on flat and curved surfaces. Then, drying of two connected capillary tubes is studied, considering the influence of different contact angle hysteresis ranges on drying dynamics. Finally, the model is applied to study drying of a dual-porosity porous medium, where phase distribution and drying rate are compared with and without contact angle hysteresis. The proposed model is shown to be capable of dealing with different contact angle hysteresis ranges accurately and of capturing the physical mechanisms during drying in different porous media including flat and curved geometries.

SUPPLEMENTARY INFORMATION

The online version contains supplementary material available at 10.1007/s11242-021-01644-9.

Using an added liquid to suppress drying defects in hard particle coatings

HYPOTHESIS

Lateral accumulation and film defects during drying of hard particle coatings is a common problem, typically solved using polymeric additives and surface active ingredients, which require further processing of the dried film. Capillary suspensions with their tunable physical properties, devoid of polymers, offer new pathways in producing uniform and defect free particulate coatings.

EXPERIMENTS

We investigated the effect of small amounts of secondary liquid on the coating's drying behavior. Stress build-up and weight loss in a temperature and humidity controlled drying chamber were simultaneously measured. Changes in the coating's reflectance and height profile over time were related with the weight loss and stress curve.

FINDINGS

Capillary suspensions dry uniformly without defects. Lateral drying is inhibited by the high yield stress, causing the coating to shrink to an even height. The bridges between particles prevent air invasion and extend the constant drying period. The liquid in the lower layers is transported to the interface via corner flow within surface pores, leading to a partially dry layer near the substrate while the pores above are still saturated. Using capillary suspensions for hard particle coatings results in more uniform, defect free films with better printing characteristics, rendering high additive content obsolete.

The Brooks and Corey Capillary Pressure Model Revisited from Pore Network Simulations of Capillarity-Controlled Invasion Percolation Process

Relating the macroscopic properties of porous media such as capillary pressure with saturation is an on-going problem in many fields, but examining their correlations with microstructural traits of the porous medium is a challenging task due to the heterogeneity of the solid matrix and the limitations of laboratory instruments. Considering a capillarity-controlled invasion percolation process, we examined the macroscopic properties as functions of matrix saturation and pore structure by applying the throat and pore network model. We obtained a relationship of the capillary pressure with the effective saturation from systematic pore network simulations. Then, we revisited and identified the microstructure parameters in the Brooks and Corey capillary pressure model. The wetting phase residual saturation is related to the ratio of standard deviation to the mean radius, the ratio of pore radius to the throat length, and pore connectivity. The size distribution index in the Brooks and Corey capillary pressure model should be more reasonably considered as a meniscus size distribution index rather than a pore size distribution index, relating this parameter with the invasion process and the structural properties. The size distribution index is associated with pore connectivity and the ratio of standard deviation to mean radius (σ0/r¯), increasing with the decline of σ0/r¯ but the same for networks with same σ0/r¯. The identified parameters of the Brooks and Corey model might be further utilized for correlations with other transport properties such as permeability.

Evaporation versus imbibition in a porous medium

Predicting and controlling the liquid dynamics in a porous medium is of large importance in numerous technological and industrial situations. We derive here a general analytical solution for the dynamics of a flat liquid front in a porous medium, considering the combined effects of capillary imbibition, gravity and evaporation. We highlight that the dynamics of the liquid front in the porous medium is controlled by two dimensionless numbers: a gravity-capillary number G and an evaporation-capillary number E. We analyze comprehensively the dynamics of the liquid front as functions of G and E, and show that the liquid front can exhibit seven kinds of dynamics classified in three types of behaviors. For each limiting case, a simplified expression of the general solution is also derived. Finally, estimations of G and E are computed to evidence the most common regimes and corresponding liquid front dynamics encountered in usual applied conditions. This is realized by investigating the influence of the liquid and porous medium properties, as well as of the atmospheric conditions, on the values of the dimensionless numbers.

Preferential Root Tropisms in 2D Wet Granular Media with Structural Inhomogeneities

We investigate certain aspects of the physical mechanisms of root growth in a granular medium and how these roots adapt to changes in water distribution induced by the presence of structural inhomogeneities in the form of solid intrusions. Physical intrusions such as a square rod added into the 2D granular medium maintain robust capillary action, pumping water from the more saturated areas at the bottom of the cell towards the less saturated areas near the top of the cell while the rest of the medium is slowly devoid of water via evaporation. The intrusion induces "preferential tropism" of roots by first generating a humidity gradient that attracts the root to grow towards it. Then it guides the roots and permits them to grow deeper into more saturated regions in the soil. This further allows more efficient access to available water in the deeper sections of the medium thereby resulting to increased plant lifetime.

Convective drying of a porous medium with a paste cover

The convective drying of a composite system made of a porous medium covered with a paste is a situation often encountered with soils, roads, building and cultural heritage materials. Here we discuss the basic mechanisms at work during the drying of a model composite system made of a homogeneous paste covering a simple granular packing. We start by reviewing the rather well-known case of the convective drying of a simple granular packing (i.e. without paste cover), which serves as a reference for physical interpretations. We show that a simple model assuming homogeneous desaturation followed by a progressive development of a dry front from the sample free surface is in agreement with observations of the internal liquid distribution variations in time. In particular, this model is able to reproduce the saturation vs. time curves of various simple granular systems, which supports our understanding of physical mechanisms at work. Then we show the detailed characteristics of drying of initially saturated model composite systems (with kaolin or cellulose paste) with the help of MRI measurements providing the liquid distribution in the sample at different times during the process up to the very last stages of drying. It appears that the granular medium is unaffected (i.e. remains saturated) during an initial period during which the paste shrinks and finally forms a sufficiently rigid porous structure which will not any more shrink later on. Then the drying process is governed by capillary effects down to very low saturation. Over a wide range of saturations both media desaturate homogeneously (within each medium) at different rates which depend on the specific porous structure of the media, so as to maintain capillary equilibrium throughout the sample. During these different stages the drying rate of the whole system remains constant. For sufficiently low saturation in the paste a dry front can develop, both in the paste and the porous medium below, and the drying rate now decreases. These results show that in a drying composite system liquid extraction can occur more or less simultaneously in the different parts of the material up to the very last stages of drying. The corresponding evolution of the distributions of liquid in the different parts of the sample also provides key information for the prediction of ion or particle transport and accumulation in the different parts of a composite system.

Strengthening and drying rate of a drying emulsion layer

From direct observations and MRI measurements we demonstrate that during the drying of a direct (oil in water) emulsion the whole system essentially concentrates homogeneously, which leads to shrinkage, without air penetration. The structure and mechanical strength (i.e. the elastic modulus) of this concentrated bulk are not significantly different from those of an emulsion directly prepared at this higher concentration. Despite this phenomenon, the drying rate continuously and rapidly decreases as the water content decreases, in contrast with the drying of a simple granular packing. This results from a concentration gradient which develops towards the free surface of the sample where the oil droplets finally coalesce, ultimately forming an oil layer covering the sample through which the water molecules have to diffuse before evaporating. Moreover, as during the process, the liquid is transported towards the free surface where it evaporates, surfactants accumulate and tend to form a thin solid layer below the oil layer, which tends to further reduce the drying rate.

Effect of geometry on the dewetting of granular chains by evaporation

Understanding evaporation or drying in granular media still remains complex despite recent advancements. Evaporation depends on liquid transport across a connected film network from the bulk to the surface. In this study, we investigate the stability of film networks as a function of the geometry of granular chains of spherical grains. Using a controlled experimental approach, we vary the grain arrangement or packing and measure the height of the liquid film network during evaporation as packing shifts from loose-packed to close-packed arrangement. This height can be calculated from an equilibrium between hydrostatic pressure and the capillary pressure difference in the vertical film network. Following a simulation approach using Surface Evolver, we evaluate the pressure variation due to dewetting of the meniscus volume in the grains in both the percolating front and evaporating front within the two-phase zone of air/water mixture. Results show good agreement between model and experiment. We find that above a "critical" packing angle, the liquid continuity is broken and films connections fragment into separate, isolated capillary bridges.

Single layer porous media with entrapped minerals for microscale studies of multiphase flow

The behaviour of minerals (i.e. salts) such as sodium chloride and calcite in porous media is very important in various applications such as weathering of artworks, oil recovery and CO2 sequestration. We report a novel method for manufacturing single layer porous media in which minerals can be entrapped in a controlled way in order to study their dissolution and recrystallization. In addition, our manufacturing method is a versatile tool for creating monomodal, bimodal or multimodal pore size microporous media with controlled porosity ranging from 25% to 50%. These micromodels allow multiphase flows to be quantitatively studied with different microscopy techniques and can serve to validate numerical models that can subsequently be extended to the 3D situation where visualization is experimentally difficult. As an example of their use, deliquescence (dissolution by moisture absorption) of entrapped NaCl crystals is studied; our results show that the invasion of the resulting salt solution is controlled by the capillary pressure within the porous network. For hydrophilic porous media, the liquid preferentially invades the small pores whereas in a hydrophobic network the large pores are filled. Consequently, after several deliquescence/drying cycles in the hydrophilic system, the salt is transported towards the outside of the porous network via small pores; in hydrophobic micromodels, no salt migration is observed. Numerical simulations based on the characteristics of our single layer pore network agree very well with the experimental results and give more insight into the dynamics of salt transport through porous media.

Experimental investigation of water distribution in a two-phase zone during gravity-dominated evaporation

We characterize the water repartition within the partially saturated (two-phase) zone (PSZ) during evaporation from mixed wettable porous media by controlling the wettability of glass beads, their sizes, and as well the surrounding relative humidity. Here, capillary numbers are low and under these conditions, the percolating front is stabilized by gravity. Using experimental and numerical analyses, we find that the PSZ saturation decreases with the Bond number, where packing of smaller particles have higher saturation values than packing made of larger particles. Results also reveal that the extent (height) of the PSZ, as well as water saturation in the PSZ, both increase with wettability. We also numerically calculate the saturation exclusively contained in connected liquid films and results show that values are less than the expected PSZ saturation. These results strongly reflect that the two-phase zone is not solely made up of connected capillary networks but also made of disconnected water clusters or pockets. Moreover, we also find that global saturation (PSZ + full wet zone) decreases with wettability, confirming that greater quantity of water is lost via evaporation with increasing hydrophilicity. These results show that connected liquid films are favored in more-hydrophilic systems while disconnected water pockets are favored in less-hydrophilic systems.

Drying in a microfluidic chip: experiments and simulations

We present an experimental micro-model of drying porous media, based on microfluidic cells made of arrays of pillars on a regular grid, and complement these experiments with a matching two-dimensional pore-network model of drying. Disorder, or small-scale heterogeneity, was introduced into the cells by randomly varying the radii of the pillars. The microfluidic chips were filled with a volatile oil and then dried horizontally, such that gravitational effects were excluded. The experimental and simulated drying rates and patterns were then compared in detail, for various levels of disorder. The geometrical features were reproduced well, although the model under-predicted the formation of trapped clusters of drying fluid. Reproducing drying rates proved to be more challenging, but improved if the additional trapped clusters were added to the model. The methods reported can be adapted to a wide range of multi-phase flow problems, and allow for the rapid development of high-precision micro-models containing tens of thousands of individual elements.

Water retention against drying with soft-particle suspensions in porous media

Polymers suspended in granular packings have a significant impact on water retention, which is important for soil irrigation and the curing of building materials. Whereas the drying rate remains constant during a long period for pure water due to capillary flow providing liquid water to the evaporating surface, we show that it is not the case for a suspension made of soft polymeric particles called microgels: The drying rate decreases immediately and significantly. By measuring the spatial water saturation and concentration of suspended particles with magnetic resonance imaging, we can explain these original trends and model the process. In low-viscosity fluids, the accumulation of particles at the free surface induces a recession of the air-liquid interface. A simple model, assuming particle transport and accumulation below the sample free surface, is able to reproduce our observations without any fitting parameters. The high viscosity of the microgel suspension inhibits flow towards the free surface and a drying front appears. We show that water vapor diffusion over a defined and increasing length sets the drying rate. These results and model allow for better controlling the drying and water retention in granular porous materials.

Drying kinetics driven by the shape of the air/water interface in a capillary channel

We look at the drying process in a simple glass channel with dominant capillary effects as is the case in microfluidics. We find drying kinetics commonly observed for confined geometry, namely a constant period followed by a falling rate period. From visualization of the air/water interface with high resolution, we observe that the drying rate decreases without a drying front progression although this is the usually accepted mechanism for confined geometries. We show with FEM that in our specific geometry the falling rate period is due to changes in the shape of the air-water interface at the free surface where most evaporation occurs. Our simulations show that the sensitivity of the drying rate to the shape of the first air-water interface from the sample free surface implies that slight changes of the wetting or pinning conditions can significantly modify the drying rate.

Simple analytical model of evapotranspiration in the presence of roots

Evaporation of water out of a soil involves complicated and well-debated mechanisms. When plant roots are added into the soil, water transfer between the soil and the outside environment is even more complicated. Indeed, plants provide an additional process of water transfer. Water is pumped by the roots, channeled to the leaf surface, and released into the surrounding air by a process called transpiration. Prediction of the evapotranspiration of water over time in the presence of roots helps keep track of the amount of water that remains in the soil. Using a controlled visual setup of a two-dimensional model soil consisting of monodisperse glass beads, we perform experiments on actual roots grown under different relative humidity conditions. We record the total water mass loss in the medium and the position of the evaporating front that forms within the medium. We then develop a simple analytical model that predicts the position of the evaporating front as a function of time as well as the total amount of water that is lost from the medium due to the combined effects of evaporation and transpiration. The model is based on fundamental principles of evaporation fluxes and includes empirical assumptions on the quantity of open stomata in the leaves, where water transpiration occurs. Comparison between the model and experimental results shows excellent prediction of the position of the evaporating front as well as the total mass loss from evapotranspiration in the presence of roots. The model also provides a way to predict the lifetime of a plant.

Depinning and dynamics of imbibition fronts in paper under increasing ambient humidity

We study the effects of ambient air humidity on the dynamics of imbibition in a paper. We observed that a quick increase of ambient air humidity leads to depinning and non-Washburn motion of wetting fronts. Specifically, we found that after depinning the wetting front moves with decreasing velocity v[proportionality](h(p)/h(D))(γ), where h(D) is the front elevation with respect to its pinned position at lower humidity h(p), while γ=/~1/3. The spatiotemporal maps of depinned front activity are established. The front motion is controlled by the dynamics of local avalanches directed at 30° to the balk flow direction. Although the roughness of the pinned wetting front is self-affine and the avalanche size distribution displays a power-law asymptotic, the roughness of the moving front becomes multiaffine a few minutes after depinning.