Experiment 8

Aim: Measurement of Heat Flux and Surface Heat Transfer Coefficient During Filmwise and
Dropwise Condensation

Apparatus: H911 Film and Dropwise Condensation Unit

Theory: The use of steam both for power production and to convey heat has a long history
and its use in these fields are likely to continue into the foreseeable future. In all applications,
the steam must be condensed as it transfers heat to a cooling medium. This could be the cold
water in the condensers of a generating station, the hot water in a heating calorifier, a sugar
solution in a sugar refinery etc. During condensation, very high heat fluxes are possible and
provided the heat can be quickly transferred from the condensing surface into the cooling
medium, steam using heat exchangers can be compact and effective.

Steam may condense onto a surface in two distinct modes, known as FILMWISE and
DROPWISE. For the same temperature difference between the steam and the surface,
dropwise condensation is several times more effective than filmwise, and for this reason the
former is desirable although in practical plants it seldom occurs for prolonged periods.

Filmwise Condensation:

Unless specially treated, most materials used in the construction of heat exchangers are
“Wettable” and during condensation a film of condensate spreads over the surface. More
vapour condenses onto the outside of this film, increasing its thickness and causing it to flow
downward and drip from the lowest points.

The heat given up by the vapour during condensation is conducted through the film to the
metal beneath and from this, to the coolant. The liquid is a comparatively poor conductor of
heat, and although the film may be relatively thin, its thermal resistance is appreciable. It is
this resistance which accounts for the large difference between the effectiveness of filmwise
an dropwise condensation.

Dropwise Condensation:

By specially treating the condensing surface the surface becomes “non-wettable” and as the
steam condenses, a large number generally spherical beads form on its surface. These beads
become larger, coalesce and then trickle downwards. The moving bead gathers all the static
beads along its downward path, becomes larger, accelerates and leaves a virtually bare
surface in its trail. The “bare” surface offers little resistance to the transfer of heat and very
high heat fluxes are therefore possible.

Unfortunately, as stated earlier, due to the nature of the materials normally used in the
construction of condensing heat exchangers, filmwise condensation is normal, but the
desirability of dropwise condensation has led to many investigations into methods which will
promote and maintain it in practical plants.

Observations:

Test No. 7
Chamber Pressure
4
kN/m2
Saturation
Temperature, t1 102
(Celcius)
Indicated Surface
28.3
Temperature, t2
Water Inlet
17.2
Temperature, t3
Water Outlet
20
Temperature, t4
Water Flow Rate,
10
g/s

Calculations:

 Steam Temperature = 100 °C

 Observed Surface Temperature = 28.3°C
 Correction for Thermocouple = 0.5°C
 Corrected Surface Temperature = 28.8 °C
 Water Inlet Temperature t3 = 17.2°C
 Water Outlet Temperature t4 = 20°C
 Water Flow Rate md = 10 gm/s

Heat Transfer Rate:

= 10*0.001*4180*(20-17.2)

= 117.04 W

Area of Heat Transfer Surface = 0.0034 m2

Heat flux = Q/A = 117.04/0.0034 = 34423.59 W/m2 = 34.4 kW/m2

Correction for Temperature Drop through Condenser Shell

= 2 x 10^(-6) * Heat Flux = 2 x 10^(-6)*34.4*1000 K = 0.0688K

Corrected Steam to Surface Temperature Difference, = 100-28.8-0.0688 = 71.1312 K

Surface Heat Transfer Coefficient:

h= 34.4*1000/71.1312 = 0.4839 kW/m2K