DROPWISE AND FILMWISE CONDENSATION APPARATUS

AIM:
 To determine the inside and outside heat transfer coefficient of Filmwise

and Dropwise condenser.

 To study the Dropwise and Filmwise condensation phenomena

APPARATUS:

Filmwise and Dropwise Condensers enclosed in a Borosilicate Glass Tube with

flow control valves, Steam generator with heating elements, Digital Temperature

Indicator with selector switch, Rotameter.

THEORY:

The processes involving phase change, like boiling and condensation, are also

very important in engineering practice. Boilers and condensers are essential

components of modern thermal power plants; so are the evaporators and

condensers in the vapor compression refrigeration cycles. The phenomenon of

boiling heat transfer has also been successfully used in the cooling of nuclear

reactors and rocket motors where the energy dissipation rates are extremely

DROPWISE AND FILMWISE CONDENSATION

large. In order to be able to design these components effectively the phenomena

of phase change processes must be well understood.

The phenomena associated with boiling and condensation is much more complex

than the convection process. This is due to the fact that latent heat effects, surface

tension, surface characteristics and other properties of two phase systems are

very significant. High heat transfer rates associated with small temperature

differences are usually involved in boiling and condensation.

Condensation Heat Transfer:

The process of condensation is the reverse of boiling. Whenever a saturated vapor

comes in contact with a surface at a lower temperature, condensation occurs.

There are two modes of condensation; filmwise, in which the condensate wets

the surface forming a continuous film which covers the entire surface and

dropwise in which the vapor

condenses into small liquid droplets of various sizes which fall down the surface

in a random fashion.

Filmwise condensation generally occurs on clean uncontaminated surfaces. In

this type of condensation the film covering the entire surface grows in thickness

as it moves down the surface by gravity. There exists a thermal gradient in the

film and so it acts as a resistance to heat transfer. In dropwise condensation a

DROPWISE AND FILMWISE CONDENSATION

large portion of the area of the plate is directly exposed to the vapor, making heat

transfer rates much larger (5 to10 times) than those in filmwise.

condensation. Although dropwise condensation would be preferred to filmwise

condensation yet it is extremely difficult to achieve or maintain. This is because

most surfaces become ‘wetted’ after being exposed to condensing vapors over a

period of time. Dropwise condensation can be obtained under controlled

conditions with the help of certain additives to the condensate and various

surface coatings but its commercial viability has not yet been proved. For this

reason the condensing equipment in use is designed on the basis of filmwise

condensation.

DROPWISE AND FILMWISE CONDENSATION

APPARATUS DESCRIPTION:
The apparatus consist of:

Steam Generator: (8 liter capacity) equipped with 2 kW heater and Pressure Gauge,

Manual Release Valve, Feed Line and Steam Line.

Dropwise Condenser:

MOC: Copper with chrome plating

Dimensions: ID (di) 16 mm

OD (do) 19 mm

Length (L) 170 mm

Filmwise Condenser:

MOC: Copper with Natural finish

Dimensions: ID (di) 16 mm

OD (do) 19 mm

Length (L) 170 mm

Temperature Indicator with Selector Switch measures the Temperature of :

T1 Steam Chamber Temp.

T2 Cooling Water In

T3 Filmwise Condenser Surface Temp

T4 Dropwise Condenser Surface Temp

T5 Cooling water outlet from film wise condensation surface

DROPWISE AND FILMWISE CONDENSATION

T6 Cooling water outlet from drop wise condensation surface

Rotameter (0.3-3.0 LPM) has been provided on the cooling water line to measure

the rate of water flowing through the condenser.

Ball valves have been provided to change the direction of cooling water flow

between either of the condensers.

DROPWISE AND FILMWISE CONDENSATION

EXPERIMENTAL PROCEDURE:

 Fill the steam generator with about 10 – 15 liter of water (preferably soft).

 Connect supply socket to the mains and switch on the heater.

 Switch on the heater while keeping the steam line and feed line valves

in closed position.

 Adjust the temperature of the steam near to the 105 – 110 OC.

 Allow the steam generation to take place.

 This may take 30 – 40 minutes depending on the initial temperature of

the feed water.

 The pressure of the generated steam will be indicated on the pressure

gauge. Note down the Pressure reading of the steam inlet.

 Now select the condenser to be tested first and open the ball valve of the

same for cooling water supply.

 Now start the supply of cooling water in the selected condenser

(Dropwise or Filmwise)

 Depending upon the type of condenser under test Dropwise or Filmwise

condensation can be visualized.

 If water flow rate is low than steam pressure in chamber will rise and

pressure gauge will read the pressure.

DROPWISE AND FILMWISE CONDENSATION

 If the water flow rate is matched than condensation will occur at more or

less at atmospheric pressure.

 Process of Dropwise and Filmwise condensation can be easily viewed

through the front glass window of main unit.

 Note down the inlet temperature of the cooling water, Outlet Cooling

water Temperature as indicated by the DTI.

 Slowly open the steam line valve and allow the steam to enter the steam

chamber.

 Observe the condensation phenomena and also note down the condenser

temperature, steam inlet temperature.

 Measure and note the cooling water flow rate through Rotameter provided.

 Repeat the above procedure for the second type of condenser.

 Use the wiper provided if the fog/ mist restricts the visualization of the

glass vessel.

DROPWISE AND FILMWISE CONDENSATION

PRECAUTIONS:

 Do not start heater supply unless water is filled in the test unit.

 Operate gently the selector switch of temperature indicator to read various

temperatures.

 Increase the temperature gradually of the heater during initial set-up

experimentation.

 Never use the heater at full wattage for longer period of time.

 Use the proper range of Rotameter.

 Operate the change over switch of temperature indicator gently from one

position to other, i.e. from 1 to 4 positions.

DROPWISE AND FILMWISE CONDENSATION

OBSERVATIONS:
Filmwise Condensation:

Cooling Water Flow Rate (mw): LPM

Temperature:

T Steam Chamber Temp:

T Cooling Water In:

T Filmwise Condenser Surface Temp:

T Cooling water outlet from film wise condensation surface

Dropwise Condensation:

Cooling Water Flow Rate (mw): LPM

Temperature:

T Steam Chamber Temp:

T Cooling Water In:

T Drop wise Condenser Surface Temp:

T Cooling water outlet from drop wise condensation surface

DROPWISE AND FILMWISE CONDENSATION

CALCULATIONS:

Normally steam will not be pressurized, but the pressure gauge reads some pressure

than properties of steam should be taken at that pressure or otherwise atmospheric

pressure will be taken.

FIRST CALCULATE THE HEAT TRANSFER COEFFICIENT INSIDE THE

CONDENSER UNDER TEST.

For this properties of water are taken at bulk mean temperature of water

i.e. (Twi + Two) / 2.

Following properties are required:

 Density of water  kg / m3

 Kinematic Viscosity  m2/ sec

 Thermal Conductivity ‘k’ kcal / hr m C

 Prandtl Number Pr

 Reynolds Number NRe =  v di / 

Where

v (=mw*4/  * di2) = (Flowrate/Area)

di = Inner Diameter of Condenser

DROPWISE AND FILMWISE CONDENSATION

If this value of NRe > 2100 then flow is turbulent, below this value flow is laminar.

Normally flow will be turbulent in the tube.

 Nusselt Number NuD = 0.023 (ReD)0.4 (Pr)0.4

 Inside heat transfer coefficient ( hi ) = NuD * k/ di kcal / hr m2 C

CALCULATE HEAT TRANSFER COEFFICIENT ON OUTER SURFACE OF THE

CONDENSER HO:

For this properties of water are taken at bulk mean temperature of condensate

(Ts + Tw) / 2.

 Density of water  kg / m3

 Kinematic Viscosity  m2/ sec

 Thermal Conductivity ‘k’ kcal / hr m C

 Prandtl Number Pr

 Reynolds Number NRe =  v di / 

Where, Ts Temperature of steam,

Tw Temperature of condenser wall

do outside diameter of condenser

 ho = 0.725 * 2 * g * k3 / ( Ts - Tw) * do

DROPWISE AND FILMWISE CONDENSATION

From these values overall heat transfer coefficient (U) can be calculated,

1/ U = 1 / hi + (di / do) (1 / ho)

U= kcal / hr m2 C

The same procedure can be repeated for another condenser.

Except for some exceptional cases overall heat transfer coefficient for dropwise

condensation will be higher than that of filmwise condensation. Results may vary from

theory to some degree due to unavoidable heat losses from the glass tube walls.

RESULT:

DROPWISE AND FILMWISE CONDENSATION

SAMPLE CALCULATION:

First calculate the heat transfer coefficient inside the condenser under test. For

this properties of water are taken at bulk mean temperature of water

i.e. (Twi + Two) / 2. Following properties are required:

PHYSICAL PROPERTIES AT WATER MEAN TEMPERATURE

Dropwise Filmwise
Physical Properties
Condenser Condenser
Steam Pressure
P 1.5 1.5
Kg/cm2
Steam Temperature
Ts 99.3 99.4
O
C
Mean Temperature
Tm 35 35
o
C
Density of Water
 993.95 993.95
kg/m3
Viscosity
µ 0.00073 0.00073
Kg/ m s
Kinematics
 0.732*10-6 0.732*10-6
Viscosity m2/ s
Cooling Water
Q 2 2
Flowrate LPM
Vol. Flowrate
m 0.000033 0.000033
m3/s
Velocity
V 0.164 0.164
m/s
Thermal
Conductivity K 0.537 0.537
kcal / hr m C
Specific Heat
CP 0.997 0.997

DROPWISE AND FILMWISE CONDENSATION

Reynolds Number

ReD =  v di / 

= 993.95*0.165*0.016/0.00073

= 3594

where

v = Velocity of Cooling Water Inside Condenser, m/s

= mw*4 /  * di2

where, mw = vol. Flowrate, m3/s

= Q/ 60000

=2/60000

=0.00003333

Q = Coo ling Water Flowrate, LPM

di = Inner Diameter of Condenser, m

 = Density of Water at mean Temperature, kg/m3

 = Viscosity of Water at mean Temperature, kg/ms

If this value of ReD > 2100 then flow is turbulent, below this value flow is

laminar.

Normally flow will be turbulent in the tube.

Prandtl Number

DROPWISE AND FILMWISE CONDENSATION

 NPr = Cp * μ / k

= 0.997*0.00073/0.537

= 4.878

Where

Cp = Specific Heat of Water,

μ = Viscosity of Water, Kg/ m s

k = Thermal Conductivity of Condenser Material, kcal/ hr m OC

Nusselt Number

NuD = 0.023 (ReD)0.4 (Pr)0.4

= 0.023 * 35940.4 * 4.8780.4

= 1.1467

Thus Inside Heat Transfer Coefficient, kcal / hr m2 C

hi = NuD * k/ di

= 1.1467*0.537/0.016

= 38.48 kcal / hr m2 C

DROPWISE AND FILMWISE CONDENSATION

Normally steam will not be pressurised, but the pressure gauge reads some

pressure than properties of steam should be taken at that pressure or otherwise

atmospheric pressure will be taken. Now calculate the heat transfer coefficient

outside the condenser under test. For this properties of condensate are taken at

bulk mean temperature of Condenser wall and the Steam Inlet Temperature

i.e. (Tw + Ts) / 2. Following properties are required:

DROPWISE AND FILMWISE CONDENSATION

 PHYSICAL PROPERTIES AT CONDENSATE MEAN TEMPERATURE

Dropwise Filmwise
Physical Properties
Condenser Condenser
Steam Pressure
P 1.5 1.5
Kg/cm2
Steam Temperature
Ts 99.3 99.4
O
C
Mean Tamp
Tm 78.45 82.2
0
C
Density of Water
 971.8 971.8
kg/m3
Viscosity
µ 0.000355 0.000355
Kg/ m s
Kinematics
 0.365*10-6 0.365*10-6
Viscosity m2/ s
Cooling Water
Q 2
Flowrate LPM
Vol. Flowrate
m 0.000033
m3/s
Velocity
V 0.164
m/s
Thermal
Conductivity K 0.579
kcal / hr m C
Specific Heat
CP 0.997

DROPWISE AND FILMWISE CONDENSATION

Calculate heat transfer coefficient on outer surface of the condenser h o.

Where, Ts Temperature of steam, Tw Temperature of condenser wall

ho = 0.725 * 2 * g * k3 / ( Ts - Tw) * do

= 0.725*2*9.81*0.579 3 /(99.3-78)*0.019

= 6.605 kcal / hr m2 C

From these values overall heat transfer coefficient (U) can be calculated,

1/ U = 1 / hi + (di / do) (1 / ho)

= 1/38.48 +(16/19)(1/6.605)

= 0.1534

Thus,

U = 6.5188 kcal / hr m2 C

The same procedure can be repeated for another condenser.

Except for some exceptional cases overall heat transfer coefficient for Dropwise

condensation will be higher than that of Filmwise condensation. Results may

DROPWISE AND FILMWISE CONDENSATION

vary from theory to some degree due to unavoidable heat losses from the glass

tube walls.

SR.NO ITEM NAME SIZE MATERIAL QTY.

USED
1. Nipple ½“ GI 3
2.  ½“9“ GI 4
3.  ½ “  24 “ GI 1
4.  ½“2“ GI 3
5.  ½“3“ GI 1
6.  ½“6“ GI 2
7.  ½“9“ Copper 1
8. Elbow ½“ 3
9. Union ½“ 1
10. Ball valve ½“ 7
11. Gate valve ½“ 1
12. Coupling ½“ 3
13. Elbow (L- ½“ 2

type)
14. Glass tube 1
15. Glass
200  150  (6
(Distance
“)
piece )
16. Metal flange 6“ 2

DROPWISE AND FILMWISE CONDENSATION

 WATER T1
INLET TCONDENSOR
DROPWISE DROPWISE
2 T4
– FILMWISE T3 STEAM
CONDENSATION APPARATUS
MOC: COPPER WITH Cr.PLATING INLET
D I = 160 mm
FILMWISE CONDENSOR
DO = 190 mm
MOC: COPPER WITH NATURAL FINISH
L = 170 mm
DI = 160 mm
DO = 190 mm
L = 170 mm

D. K. Scientific Industries
4, Ashoka Chambers; Nr. Lions Hall, Mithakhali Six Roads;
Ellisebridge, Ahmedabad – 380 006.
Ph.: (079) 6469471, 72 Fax: (079) 6469481

DROPWISE AND FILMWISE CONDENSATION