Abstract

Vapor may condense onto a cooled surface in two distinct modes known as filmwise and
dropwise. At the same temperature difference between the vapor and the surface , dropwise
condensation is more effective than filmwise. The process of dropwise condensation is enhanced
by the special water cooled condenser surface finish that prevents wetting of the surface. The
presence of air insteam vapour significantly reduces the heat transfer. This experiment would be
used in any industry which is trying to increase the efficiency of heat transfer. In this experiment
, we were going to determined the filmwise and dropwise heat flux and the surface heat transfer
coefficient at constant pressure. Condensation occurs when vapor changes to liquid state with a
large heat-transfer coefficient. Filmwise condensation occurs on a vertical or horizontal plane
when a film of condensate is formed on surface and flows by action of gravity. Dropwise
condensation occurs when small drops formed on surface. The heat transfer coefficient can be
calculated by using Nusselt equation.
INTRODUCTION

When the heat from steam is transfered either to the product or to the surrounding , the
steam condenses on the cold surfaces. This condensation of steam can take place in two-ways ,
dropwise and filmwise. Dropwise condensation is always preferred over the filmwise type as its
offers a better rate of heat transfer.

In all applications, the steam must be condensed as its transfers heat to a cooling medium
which could be cold water in a condenser of generating station, hot water in a heating calorifier
or sugar solution in a sugar refinery. During condensation very high high heat fluxes are possible
and provided that the heat can be quickly transferred from the condensing surface into the
cooling medium, the heat exchangers can be compact and effective.

In filmwise condensation, the surface over which the steam condenses is wet-able and
hence, as the steam condenses, a film of condensate is formed. The filmwise condensation results
in low heat transfer rate as the film of condensate impedes the heat transfer.

For dropwise condensation , its takes place when the surface over which condensation
takes place is non-wetable. When the steam condense, the droplets are formed. When the
droplets become bigger, they simply fall under gravity. In dropwise condensation, high heat
transfer rate are achieved and hence, many times, chemicals are used to ensure that condensation
take place drop wise.

The SOLTEQ Film & Dropwise Condensation Unit (Model: HE163) is designed to help
student to understand several key aspects in condensation topic, in particular the process of
filmwise and dropwise condensation. It allows students to visualize both phenomena and
perform a few experiments to demonstrate both concepts.
Objective

Experiment 1 : To demonstrate the filmwise and dropwise condensation.

Experiment 2 : To determine the filmwise heat flux and surface heat transfer coefficient at
constant pressure.

Experiment 3 : To determine the dropwise heat flux and surface heat transfer coefficient at
constant pressure.

Theory

Condensation Heat Transfer:

Condensation heat transfer is a vital process in Process and Power Generation industries. Over a
hundreds years, our understanding of the condensation process has gradually improved. Theories
and models have become more accurate and are now applicable to a wider range of conditions.

Condensation:

There are two models of condensation, which are filmwise and dropwise condensation. Filmwise
is currently used by industry , while dropwise is an alternateive which is under development
because its offers attractive higher rates of heat transfer by preventing the build up of the
insulating liquid layer found in filmwise condensation.

Mechanism of Condensation:

Condensation of vapor to a liquid and vaporization of a liquid to a vapor both involve a

change of phase of a liquid with large heat-transfer coefficients. Condensation occurs when a
saturated vapor such as steam comes in contact with a solid whose surface temperature is below
the saturation temperature, to form a liquid such as water.

Normally, when a vapor condensed on surface such as a vertical or horizontal tube or other
surface, a film condensate is formed on the surface and flows over the surface by the action of
gravity. It is this film of liquid between the surface and the vapor that forms the main resistance
to heat-transfer. This is called filmwise condensation.

Another type of condensation, dropwise condensation, can occur, where small drops are formed
on the surface. These drops grow and coalesce, and the liquid flows from the surface. During this
condensation, large areas of tube are devoid of any liquid and are exposed directly to the vapor.
Very high rates of heat-transfer occur on these bare areas. The average heat transfer coefficient
for dropwise condensation is five to 10 times larger than the filmwise coefficients.

Dropwise condensation can be promoted by making the surface non-wetting (via coating).
However dropwise condensation is difficult to maintain in industrial applications due to
oxidation, fouling and degradation of coating, and eventually film condensation occurs.
Therefore, condenser designs are often based on the assumption of filmwise condensation.

Film-Condensation coefficients for vertical surfaces.

Film-type condensation on a vertical wall or tube can be analyze analytically by assuming

laminar flow of the condensate film down the wall. The film thickness is zero at the top of the
wall or tube and increases in thickness as its flows downward because of the condensation.
Nusselt assume that the heat-transfer from the condensation of the vapor, a final expression can
be obtained for the average heat-transfer coefficient over the whole surfaces.
Apparatus

SOLTEQ Film & Dropwise Condensation Unit (Model: HE163)

EXPERIMENTAL PROCEDURE

General Start-up Procedure

1. The main switch was ensured in the off position.

2. The power regulator knobs was turned fully anti-clockwise to set the
power to minimum.
3. Valves V1 to V6 was checked to make sure it is closed.
4. The chamber was filled with distilled water until the water level stays
between the heater and baffle plates. The heater was ensure to fully
immersed in the water throughout the experiment. Water could be filled
into the chamber through the drain valve with the vent valve, V4 opened.
Then, close the vent valve, V4.
5. The water flow rate to the condenser was adjusted by controlling the
control valve according to the experimental procedure.
6. The main switch and the heater switch was turned on. The heater power
was set by rotating the power regulator clockwise to increase the heating
power.
7. The water temperature reading was observed ; it should increase when the
water starts to heat up.
8. The water was heated to boiling point until the pressure reaches 1.02 -1.01
bar. Valve V1 was immedietly opened and followed by valve V5 for 1
minutes to vacuum out the air inside the condenser. The both valve V1 and
V5 were closed.
9. The system was let to stabilize. All the relevan measurements for the
experimental purpose was collected.
 General Shut-down Procedure

1. The voltage control knob was turned to 0 Volt position by turning the
knob fully anti-clockwise. The cooling water was kept flowing for at least
5 minutes through the condensers to cold them down.
2. The main plug and the power supply was switched off. The the power
supply cable was unplugged.
3. The water supply was closed and the cooling water connection tube is
connected if necessary. Otherwise , the connection was left for the next
experiment.
4. The water inside the chamber was discharged by using the discharge
valve.

Experiment 1 : DEMONSTRATION OF FILMWISE AND DROPWISE CONDENSATION

Procedure:

1. The basic procedure as written in section general set up procedure is followed. The
equipment was ensure to connect to the service unit.

Experiment 2 : THE FILMWISE HEAT FLUX AND SURFACE HEAT TRANSFER

COEFFICIENT DETERMINATION AT CONSTANT PRESSURE.

Procedure:

1. The cooling water was circulated through the filmwise condenser starting with a
minimum of 0.1 LPM
2. The heater power was adjusted to obtain the desired pressure at 1.01 bar.
3. When the condition is stabilized, the steam (Tsat) & surface temperature (Tsurf) , Tin(T1)
and Tout(T2) and the flowrate was recorded.
Experiment 3: THE DROPWISE HEAT FLUX AND SURFACE HEAT TRANSFER
COEFFICIENT DETERMINATION AT CONSTANT PRESSURE.

Procedure:

1. The cooling water was circulated through the dropwise condenser starting with a
minimum value of 0.4 LPM.
2. The heater power was adjusted to obtain the desired pressure of 1.01 bar.
3. When the condition is stabilized, the steam (Tsat) & surface temperature (Tsurf) ,
Tin(T3) and Tout(T4) and the flowrate was recorded.
Calculation

Formula used :

1. Heat remove from the condensation , qx = 𝒎̇CΔT

𝜟𝒕₁−𝜟𝒕₂
2. Log mean temperature difference, ΔTm= 𝜟𝒕₁
𝐥𝐧
𝜟𝒕₂
𝒒𝒙
3. Heat flux, Φ= 𝝅𝒅𝟐
𝝅𝒅𝑳+
𝟒

𝜱
4. Heat transfer coefficient, U = 𝚫𝐓𝐦

Where

 Diameter of the condenser , d=0.0127m

 Length of the condenser , L= 0.098m
 Speicific heat capacity of water, C= 4186 J/m2K
Discussion

In this experiment , we were determined to demonstrate the filmwise and dropwise condensation
and also calculate the heat flux as well as the surface heat coefficient. We first done the general
setup procedure before proceed with the experiment. After we ensure that the general setup has
done properly , we then proceed with experiment 1. For experiment 1 , the procedure is the same
with the general setup and collect the data.

After we done collecting data for experiment 1 , we continue with experiment 2 which is The
Filmwise Heat Flux and Surface Heat Transfer Coefficient Determination. For this experiment ,
we circulate the cooling water through the filmwise condenser starting with a minimum value of
0.1LPM. Then we adjusted the heater power so that we can obtained the desired pressure which
is at 1.01 bar. We take the reading of the temperature in(T1), Tout(T2), Tsat , Tsurf and also the
flowrate of the system. Figure 1 display graph which represents the heat flux for filmwise
condensation. After that , we calculate the heat flux and surface heat transfer with the formula
given. Figure 2 display graph which represents the surface heat coefficient versus the
temperature difference. Both of these graph shows that, heat flux and the surface heat coefficient
increases with different temperature.

Next, we continue with experiment 3 which is The Dropwise Heat Flux and Surface Heat
Coefficient Determination at Constant Pressure. Different from filmwise condensation , we
started the experiment by using a minimum value of 0.4 LPM of cooling water circulated
through the dropwise condenser. Then we adjusted the heater power to get the pressure of 1.01
bar before we can get the data. When the condition stabilized , we collected the same data from
experiment 2. By using all the data collected , we can calculated the heat flux and surface heat
transfer for dropwise condensation. Figure 3 , shows the graph for heat flux for dropwise
condensation while figure 4 display graph which represents the surface heat coefficient versus
temperature difference. Both of these graph shows an increases with difference temperature.
Unfortunately we did not get the nice straight line graph. There might be some eror while doing
this experiment. Probably during the data collection , the system may not stablilize completely
yet, as it takes a longer time to make sure that the system was completely stabilize. We might be
not getting the exact data for temperature and the flow rate. To prevent that from happen , we
should wait a little longer so that we can get the perfect data. Despite of not getting the perfect
straight line graph, the graph still showing that the heat flux and the surface heat transfer is
increasing with temperature difference.

For filmwise condensation , the film formed on the surface offers a thermal resistance to heat
transfer. Due to low thermal conductivity of the film ,the rate of the heat transfer from vapor to
surface are reduced. While for dropwise condensation , the vapor condense in the form of
droplets which grow in size and finally they roll of the surface under the influence of gravity.
Thus there is no thermal resistance due to film in case of drop condensation and the vapor
directly comes in contact with the surface.

Conclusion

In conclusion , dropwise condensation is a more effective method of heat transfer than filmwise
condensation , and the presence of air in steam vapour significantly reduces the heat transfer.

Reference

1. Https://www.tecquipment.com
2. https://www.forbesmarshall.com
3. https://www.quora.com
4. Heat and mass transfer textbook 5th edition.
 Experiment 2

Flowrate ( Power Tin Tout Tsat Tsurf Tsat (°C) - Tsurf ( ΔTm Φ U (W/m2
LPM ) (W) (°C) (°C) (°C) (°C) °C) (°C) (W/m2) K)
0.1 177 32.1 32.9 68.3 31.7 36.3 35.79 1382.6 38.63
0.2 166 32.2 32.5 70.3 31.9 38.4 37.95 1036.9 27.32
0.3 175 32.1 32.7 69.8 31.5 38.3 37.39 3110.9 83.16
0.4 213 32.4 33.5 69.6 30.9 38.7 36.65 691.4 207.47
0.5 218 32.7 34.8 70.3 30.7 39.6 36.54 1814.7 496.55
0.6 229 32.6 34.8 70.8 29.9 40.9 37.09 22814 615.0097

Heat Flux Φ vs Temperature Difference

25000

20000

15000

Φ (W/m2)
10000

5000

0
36 37 38 39 40 41 42

Figure 1
 Surface Heat Transfer Coefficient vs Temperature
Difference
700

600

500

400

300 U (W/m2 K)

200

100

0
36 37 38 39 40 41 42

Figure 2
 Experiment 3

Flowrate Power Tin Tout Tsat Tsurf Tsat (°C) - Tsurf ΔTm Φ (W/m2) U
(LPM) (W) (°C) (°C) (°C) (°C) (°C) (°C) (w/m2K)
0.4 127 24.9 33.5 70.3 31.3 39 40.95 59453.84 1451.86
0.8 143 32.5 33.6 70.1 31.2 38.9 37.05 15207.97 410.47
1.2 132 32.3 33.4 70 31.3 38.7 37.15 22813.68 614.096
1.6 145 32.2 33.4 70.5 31 39.5 37.69 5530.59 146.74
2 158 32.3 33.6 70.8 31.2 39.6 37.85 44936.045 1187.21
2.4 155 32.1 33.5 70.6 31 39.6 37.79 58071.19 1536.68

Heat Flux Φ vs Temperature Different

70000
60000
50000
40000
30000 Φ (W/m2)
20000
10000
0
38.6 38.8 39 39.2 39.4 39.6 39.8

Figure 3

Surface Heat Transfer Coefficient vs

Temperature Difference
1800
1600
1400
1200
1000
800 U (w/m2K)
600
400
200
0
38.6 38.8 39 39.2 39.4 39.6 39.8

Figure 4
Experiment 1
Calculation

Experiment 2:

[0.1LPM]

(𝑇sat - Tin ) - (Tsat-Tout)

ΔTm = (𝑇𝑠𝑎𝑡−𝑇𝑖𝑛)
ln
(𝑇𝑠𝑎𝑡−𝑇𝑜𝑢𝑡)

(68.3°𝐶−32.1°𝐶)−(68.3°𝐶−32.9°𝐶)
ΔTm = 68.3°𝐶−32.1°𝐶
ln
68.3°𝐶−32.9°𝐶

= 35.79°C

̇
qx = 𝑚𝐶∆𝑇

= (0.1 kg/min)(4186 J/kg.K)(32.9 K -32.1K)(1min/60 sec)

= 5.5813 J/s @ W
𝑞𝑥
Φ= 𝜋𝑑2
𝜋𝑑𝐿+
4

5.5813 𝑊
= 0.01272 𝑚
𝜋(0.0127𝑚)(0.098𝑚)+(𝜋)( )
𝑎

= 1382.64 W/m2
𝛷
U = ΔTm

1382.64 W/m2
= 35.79𝐾

= 38.63 W/m2K

Using the same formula to calculate for 0.2LPM , 0.3LPM, 0.4LPM , 0.5LPM and 0.6LPM.

The same formula was used to calculate for dropwise condensation part.
Tin

Tout
SOLTEQ Film & Dropwise Condensation Unit (Model: HE163)