Over the last half of the twentieth century, a number of purely empirical and mechanism-based correlations have been developed for pool nucleate boiling. Empirical correlations differ from each other substantially with respect to the functional dependence of heat flux on fluid and surface properties, including gravity. The mechanism-based correlations require knowledge of the number density of active sites, bubble diameter at departure, and bubble-release frequency. However, because of the complex nature of the subprocesses involved, it has not been possible to develop comprehensive models or correlations for these parameters. This, in turn, has led to the pessimistic view that mechanistic prediction of nucleate boiling is a hopeless task. However, there is an alternative to the past approaches—complete numerical simulation of the boiling process. Value of this approach for bubble dynamics and associated heat transfer is shown through excellent agreement of predictions with data obtained on microfabricated surfaces on which active nucleation sites can be controlled.

A numerical method is presented for simulating film boiling on an immersed (or irregularly shaped) solid surface. The level set formulation for tracking the phase interfaces is modified to include the effect of phase change at the liquid–vapor interface and to treat the no-slip condition at the fluid–solid interface. The boundary or matching conditions at the phase interfaces are accurately imposed by incorporating the ghost fluid approach based on a sharp-interface representation. The numerical method is tested through computations of bubble rise in a stationary liquid, single-phase fluid flow past a circular cylinder, and film boiling on a horizontal cylinder.