Film and Drop wise Condensation

Objectives: -
a) To study the effect of cold stream flow rate on the rate of steam condensation.
b) To determine the individual film transfer coefficient.
c) To compare the experimental and theoretical values of the overall heat transfer
coefficient in case of
I. Film condensation
II. Dropwise condensation

Procedure: -
 Note the room temperature.
 Open all the valves and drain all the water already present.
 Set the apparatus so that the water only flows through rough pipe.
 Open the water flow rate valve and pass it through the rough pipe.
 Open the steam valve and try to set the pressure at I atm in the chamber by
placing a partially filled funnel at the top. The water should stay in the funnel
in order to prevail atmospheric conditions.
 Steam condenses in the form of film and condensate is obtained at the
bottom: Measure the mass flow rate and temperature of water (at inlet and
and outlet) and condensate.
 Change the cold-water flow rate and do same. Take 3 to 4 more readings.
 Set the apparatus, so that the cold-water stream flows through the polished
pipe only.
 Similar to above take 4 to 5 readings for different water flows.

OBSERVATIONS AND CALCULATIONS:

Room temperature TR= 25 °C

ho=0.725[k3ρ2λg/DµΔT]1/4

All values of k,µ & ρ must be calculated at

tf=Ts-0.75ΔT
Here,

λ = Latent heat of condensation of water, Btu/lb

 ρ = Density of the condensate lb/ft3

k =thermal conductivity of the condensed vapour, Btu/(f) (h)(F)

µ =Viscosity of the condensate film, lb/ft-h

D = Outside diameter of the pipe, ft

g = acceleration due to gravity = 4.18 x 10 ft/h2

INSIDE (WATER SIDE) HEAT TRANSFER COEFFICIENT = hi = ?

Assuming turbulent flow (and) forced convections we have

0.8 0.2
hi= 150 (1 + 0.011 Tm ) u /d , Btu/(h)( )(°F)

d =inside diameter of the pipe in.

u = velocity of water, ft/s

temperature of hot water +temperature of cold water

Tm= , °F
2

Film Wise Condensation:

No of Mass Velocity of Mass Temp. of Mean Temp. of the Condensate

Obs. Flow rate Water Flow rate outlet hot bulk condensate flow rate
of Cold of hot water temp. Te
water u water
To Tm (°F)
Gcold G
(°C)
(lb/s) (ft/s) (lb/s) (lb/s)
(°F)

1 150 2000 116.6 197.2 104.9 131 7.93

2 250 3276 114.8 323 104 123.8 8.99

3 300 3351 109.4 330.4 101.3 118.4 11.63

Here,
 mass of water collected
G= lb/s
collection time

G = uAp⇒ u = G/ Ap

A = π d²/4 = ft2

p = density of water, lb/ft3

Tm= (To + TR)/2

No of Obs. ΔT = Ts-T tf k P µ ho hi
(°F)
(°F) at tf at tf at tf Btu/(h-t²- Btu/(h-ft²-
°F) °F)

1 94 141.5 .375 61.38 .8 1600.5 2.64*10^5

2 98.1 138.43 .374 61.4 .813 1575 4.21*10^5

3 102.2 135.35 .373 61.4 .812 1551.92 4.23*10^5

Where

ΔT temperature difference b/w vapor and metal, F

= Tvapour - Tmetal= Ts-T

We don't know the value of metal temperature, so we use

Tmetal =T= (Te+ Tm)/2.0

No of 0₁ 02 0m= ΔT=T0-TR Cpof Q= U= Q/A00m

Obs. 01−02 Water GCpΔT
Ts-TR T4-TO (Btu/F-lb) Btu/lb-ft2.F
ln ( 01−02 )
(Btu/s)
(°F)

(°F) (°F)
(°F)
 1 118.8 95.4 106.67 23.4 1 4614.5 2.74*10^4

2 118.8 97.2 107.6 21.6 1 6976.5 4.1*10^4

3 118.8 102.5 110.4 16.4 1 5418.6 3.06*10^4

Drop-wise Condensation:
No of Mass Velocity of Mass Temp. of Mean Temp. of the Condensate
Obs. Flow rate Water Flow rate outlet hot bulk condensate flow rate
of Cold of hot water temp. Te
water u water
To Tm (°F)
Gcold G
(°C)
(lb/s) (ft/s) (lb/s) (lb/s)
(°F)

1 150 1765 122 176 107.6 156.3 29.07

2 250 3010 199.3 295 106.3 136.2 32.25

3 300 3824.5 112 374.5 102.6 134.6 32.78

Here,

mass of water collected

G= lb/s
collection time

G = uAp⇒ u = G/ Ap

A = π d²/4 = ft2

p = density of water, lb/ft3

Tm= (To + TR)/2

No of Obs. ΔT = Ts-T tf k P µ ho hi
(°F)
(°F) at tf at tf at tf Btu/(h-t²- Btu/(h-ft²-
°F) °F)

1 80.1 141.5 .378 61.32 .77 1691 2.64*10^5

2 90.3 138.43 .376 61.38 .78 1628.8 3.98*10^5

3 93.4 135.35 .375 61.39 .80 1603.2 4.75*10^5

Where

ΔT temperature difference b/w vapor and metal, F

= Tvapour - Tmetal= Ts-T

We don't know the value of metal temperature, so we use

Tmetal =T= (Te+ Tm)/2.0

No of 0₁ 0₁ 0m= ΔT=T0-TR Cpof Q= U= Q/A00m

Obs. 01−02 Water GCpΔT
Ts-TR T4-To (Btu/F-lb) Btu/lb-ft2.F
ln ( 01−02 )
(Btu/s)
(°F)

(°F) (°F)
(°F)

1 118.8 90 103.7 28.8 1 5069 3.09*10^4

2 118.8 92.7 105.21 26.1 1 7699.5 4.63*10^4

3 118.8 99.9 109 18.6 1 6972 4.09*10^4

where Ao = area outside surface = pi*DL ,ft3

L= effective length of the tube, ft

Results and Graphs:

Condensation (Rough pipe)

1700
1680
1660
1640
1620
ho

1600
1580
1560
1540
150 250 300
Flow rate of cold fluid

Condensation(Smooth Pipe)
1610
1600
1590
1580
1570
ho

1560
1550
1540
1530
1520
150 250 300
Flow rate of cold fluid

Discussion:
 A simulation model based on the mass and energy balances for a plate heat exchanger has
been established. Comparisons with measured data reveal a reasonable accuracy of the
 calculations for both film wise and dropwise condensation. A further improvement of the
model is expected with extensions that account for another effect on the heat transfer, such as
drainage limitations, the vapour shear or pressure drop effects.
 The model was assessed in parameter variations, where the influence of temperature
difference, oil flow, pressure and some model parameters on the condensation performance
was analyzed. Effects of the important operational parameters pressure and temperature
difference on the heat flux have shown that the model is useful over a certain range of
parameters, but has to be improved for high heat fluxes to achieve a better fit to the
experimental data. Concerning the model parameters, the maximum condensate droplet radius
(before it slides or falls down) has to be known better for good modeling results. For the
nucleation radius only the order of magnitude is relevant.
 It was shown that with a modern high contact angle surface, such as the Ni-P-PFA coating,
considerably higher heat fluxes can be obtained while they stay in the dropwise condensation
regime, compared to previous surfaces, which quickly transit to the film wise condensation
regime.