DROPWISE AND FILMWISE CONDENSATION UNIT

AIM: To find the heat transfer coefficient for drop wise condensation and
filmwise condensation process.

THEORY:
In all applications, the steam must be condensed as it transfer heat to a cooling
medium, e.g. cold water in the condenser of a generating station, hot water in a
heating calorifier, sugar refinery, etc. During condensation very high heat fluxes are
possible & provided the heat can be quickly transferred from the condensing surface
to the cooling medium, heat exchangers using steam can be compact & effective.
Steam may condense on to a surface in two distinct modes, known as "film
wise" & "Dropwise". For the same temperature difference between the steam & the
surface, drop u se condensation is much more effective than film wise & for this
reason the former is desirable although in practical plants it rarely occurs for
prolonged periods.

FILMWISE CONDENSATION:
Unless specially treated, most materials are wettable & as condensation occurs a film
condensate spreads over the surface. The thickness of the film depends upon a
numbers of factors, e.g. the rate of condensation, the viscosity of the condensate and
whether the surface is vertical or horizontal, etc.
Fresh vapour condenses on to the outside of the film & heat is transferred by
conduction through the film to the metal surface beneath. As the film thickness it
flows downward & drips from the low points leaving the film intact & at an
equilibrium thickness. The film of liquid is a barrier to the transfer of heat and its

Dropwise and Filmwise condensation

resistance accounts for most of the difference between the effectiveness of film wise
and drops wise condensation.

DROPWISE CONDENSATION:

By specially treating the condensing surface the contact angle can be changed and
the surface becomes ‘non - wettable’. As the steam condenses, a large number of
generally spherical beads cover the surface. As condensation proceeds, the beads
become larger, coalesce, and then strike downwards over the surface. The moving
bead gathers all the static beads along its downward in its trail. The 'bare' surface
offers very little resistance to the transfer of heat and very high heat fluxes are
therefore possible. Unfortunately, due to the nature of the material used in the
construction of condensing heat exchangers, film wise condensation is normal.
(Although many bare metal surface are 'non- wetable’ this is not true of the oxide
film which quickly covers the bare material)

DESCRIPTION:
The equipment consists of a metallic container in which steam generation lakes
place. The lower portion houses suitable electric heater for steam generation. A
special arrangement is provided for the container for filling the water. The glass
cylinder houses two water cooled copper condensers, one of which is chromium
plated to promote drop wise condensation and the other is in its natural state to give
film wise condensation. A connection for pressure gauge is provided. Separate
connections of two condensers for passing water are provided. One rotameter with
appropriate piping can be used for measuring water flow ; rate in one of the
condensers under test. A digital temperature indicator provided has multipoint
connections, which measures temperatures of steam, two condensers, water inlet &
outlet temperature of condenser water flows.

Dropwise and Filmwise condensation

SCHEMATIC DIAGRAM OF CONDENSATION UNIT :

Fig. 1 Condensation in drop and film forms

1. Steam generator
2. Water level
3. Rota meter
4. Steam pressure
5. Condensers
6. Temperature indicator
7. Selector switch
8. Heater control
9. Main switch

UTILITIES REQUIRED:

Water supply 5 lit/min (approx.)

Electricity Supply: 1 Phase, 220 V AC, 1.5 kW.
Table for set-up support.

Dropwise and Filmwise condensation

EXPERIMENTAL PROCEDURE:

1. Fill water in steam generator by opening the valve.

2. Start water flow through one of the condensers which is to be tested and note
down water flow rate in rotameter. Ensure that during measurement, water is
flowing only through the condenser under test and second valve is closed.
3. Connect supply socket to mains and switch ON the heater switch.
4. Slowly steam generation will start in the steam generator of the unit and the
steam rises to test section gets condensed on the tubes and falls down in the
cylinder.
5. Depending upon type of condenser under test dropwise or filmwise can be
visualised.
6. If the water flow rate is low then steam pressure in the chamber will rise and
pressure gauge will read the pressure. If the water flow rate is matched then
condensation will occur at more or less atmospheric pressure or upto 1 kg
pressure.
7. Observations like temperatures, water flow rates, pressure are noted down in
the observations table at the end of each set.

EQUIPMENT DATA:

Condensers = One chromium plated for drop wise condensation & one
natural finish for film wise condensation otherwise
identical in construction.

Dropwise and Filmwise condensation

Dimension = 20 mm outer dia. 160 mm length, fabricated from copper
with reverse flow in concentric tubes, fitted with
temperature sensor for surface temp, measurement.
Main Unit = M.S. Fabricated construction comprising test section &
steam generation section. Test section provided with glass
cylinder for visualization of the process.
Heating Elements = Suitable water heater.
Instrumentation = 1) Temperature Indicator: Digital 0-199.9°C & least
count 0.1 °C with multichannel switch.
2) Temperature Sensors: RTD PT-100 Type.
3) Rotameter : Standard Make 100 LPH capacity for
measuring water flow rate.
4) Pressure Gauge : Dial type 0-2 Kg/cm2
FORMULAE:

For plain condenser

4𝑚𝑤
Red =
𝜋𝐷𝑖 𝜌1 𝑉1

Nul = 0.023. (𝑅𝑒𝑑 )0.08 . (𝑃𝑟)0.4

𝑁𝑢𝑙 .𝐾 𝐾𝑐𝑎𝑙 𝑊
and hi = 0 0
𝐿 ℎ𝑟.𝑀2 𝐶 𝑚2 𝐶
0.25
 P2 2 .g .k 2 3 
ho = 0.943  
 (Ts − Tw) L 

Where g = Acc. due to gravity = 9.8m/sec. = 9.8x 3600m/hr

L = Length of condenser = 160 mm.

Dropwise and Filmwise condensation

From these values overall Heat Transfer coefficient (U) can be calculated.
1 1 𝐷𝑖 1
𝑈
=
ℎ𝑖
+ (𝐷 × ℎ )Kcal/hr-m2-0C
0 𝑜

For plated condenser

4𝑚𝑤
Red =
𝜋𝐷𝑖 𝑃1 𝑉1

Nul = 0.023. (𝑅𝑒𝑑 )0.08 . (𝑃𝑟)0.4

𝑁𝑢𝑙 .𝐾 𝐾𝑐𝑎𝑙 𝑊
and hi = 0 0
𝐿 ℎ𝑟.𝑀2 𝐶 𝑚2 𝐶
0.25
 P2 2 .g .k 2 3 
ho = 0.943  
 (Ts − Tw) L 

Where g = Acc. due to gravity = 9.8m/sec. = 9.8x 3600m/hr

L = Length of condenser = 160 mm.
From these values overall Heat Transfer coefficient (U) can be calculated.
1 1 𝐷𝑖 1
= +( × )Kcal/hr-m2-0C
𝑈 ℎ𝑖 𝐷0 ℎ 𝑜

1 𝐷𝑖 1 4.1868
=[ +( × )] km/hr- m2-0C
ℎ𝑖 𝐷0 ℎ 0 3600

OBSERVATIONS & CALCULATIONS:

Dropwise and Filmwise condensation

Sr. No.

Steam Pressure

kg/cm2

Condenser

Under Test

Water Flow

Rate LPH

TEMPERATURE:

Plated Condenser
Outer Surface

Plain Condenser

Outer Surface

Steam

Water Inlet
to Condenser

Water Outlet
Plated Condenser

Water Outlet
Plain Condenser

CALCULATION

Dropwise and Filmwise condensation

Normally steam will not be pressurized. But if pressure gauge reads some pressure
then properties of steam should be taken at that pressure or other wise atmospheric
pressure would be taken.

We will first calculate the heal transfer coefficient inside the condenser under test.
For this properties of water are taken at bulk mean temperature of water i.e. (T wi
+Two)/2 Where Twi and Two are water inlet & outlet temperatures.

Following properties are required. :

p1 = Density of water kg/m3

V1 = Kinematics Viscosity m2 /sec.
K1 = Thermal conductivity kcal/hr -m °C. (W /m - °C )
Pr = Prandtl number.

Now calculate Reynold’s number.

4𝑚𝑤
Red = -1
𝜋𝐷𝑖 𝑃1 𝑉1

If this value of Re  2100 then flow is turbulent and below this value flow is laminar.

Normally flow will be turbulent in the tube.

Now Nusselt Number.

Nul = 0.023. (Red) 0.8 . (Pr) 0.4

𝑁𝑢𝑙 .𝐾 𝐾𝑐𝑎𝑙 𝑊
and hi = 0
𝐿 𝑟ℎ.𝑚20 𝐶 𝑚2 𝐶

Now calculate heat transfer coefficient on outer surface of the condenser (h o), For
this properties of water are taken at bulk mean temperature of condensate i.e.

Dropwise and Filmwise condensation

 (𝑇𝑠 + 𝑇𝑤 )0 𝐶
0 = 𝑇2 0 𝐶
𝑚2 𝐶
Properties needed are
i) ρ2 = Density of water Kgm/m3
ii) K2 = Thermal Conductivity Kcal/hr-m0C (W/m-0C)
iii) 𝜇 = Viscosity of condensate Kgf- sec/m2. (Kg/m.s)
iv) 𝜆 = Heat of evaporation Kcal/Kg. (540 kcal/kg)
0.25
𝜆𝜌2 2 . 𝑔. 𝑘2 3
ℎ𝑜 = 0.943 [ ]
(𝑇𝑠 − 𝑇𝑤 )𝜇𝐼

From these values overall Heat Transfer coefficient (U) can be calculated.

1 1 𝐷𝑖 1
= +( × ) Kcal/hr-m2-0C
𝑈 ℎ𝑖 𝐷0 ℎ𝑜

Same procedure can be repeated for other condenser.

Except for some exceptional cases overall heat transfer coefficient for Dropwise
Condensation will be higher than that of film wise condensation.

Results may vary from theory in some degree due to unavoidable heat losses.

Where

Di = Inner Dia of condenser.

= 1.7 cms.

hi = Inside Heat Transfer Coefficient.

Ts = Temperature of steam °C.

Dropwise and Filmwise condensation

Tw = Temperature of condenser wall °C.

g = Acc. due to gravity = 9.8 m/sec". = 1.27 x 10X m/hr2

L = Length of condenser = 160mm.

PRECAUTIONS & MAINTENANCE INSTRUCTIONS:

1. Use the stabilize A.C. Single Phase supply only.

2. Never switch on mains power supply before ensuring that all the
ON/OFF switches given on the panel are at OFF position.

3. Voltage to heater start and increase slowly.

4. Keep all the assembly undisturbed.

5. Never run the apparatus if power supply is less than 180 volts and above
than 240 volts.

6. Operate selector switch of temperature indicator gently.

7. Do not start heater supply unless water is filled in the test uni t.

8. Always keep the apparatus free from dust.

There is a possibility of getting abrupt result if the supply voltage is

fluctuating or if the satisfactory steady state condition is not reached.

Dropwise and Filmwise condensation

TROUBLE SHOOTING:

1. If electric panel is not showing the input on the mains light. Check the
fuse and also check the main supply.

2. If D.T.I displays “1" on the screen check the computer socket if loose
tight it

3. If temperature of any sensor is not displays in D.T.I check the

connection and rectify that.

4. Voltmeter showing the voltage given to heater but ampere meter does
not. Tight the heater socket & switch if ok it means heater burned.

Dropwise and Filmwise condensation

 SAMPLE CALCULATIONS:

STANDARD DATA:
O.D of heat transfer surface. d = 19mm
Length of heat transfer surface, L = 175mm
HT area =  dL = (19 x 10-3) (175 x 10-3)
= 0.0104445 m2
Steam tap .T = 111.50C

FILM WISE CONDENSATION:

Condensation surface temp., Ts = 890C average

Water inlet tap, Twi = 27.60C
Water outlet tap. Two = 35.80C
Mass flow rate of cooling water. Mw = 86.480C
Steam condensed = 252g in 8 min.
 Rate of steam condensate = 252/8=31.5g/min.
Ms = 1.89kg/hr.

Latent heat of steam (at T) = 2230kJ/kg= 533.5 kcal/kg.

Cpwater = 4.174kJ/kg kcal/kg0C

Properties of saturated water at 100°C

𝜆 = 533.5 kcal/kg
 = 958.4 kg/M3
k = 0.683 w/m-k = 0.5873 kcal/h-m-°C at ar. tap of (111+89)/2
 = 282.4 x 10-6 N-s/m2 = 1000C
Pr = 1.75

Heat Flux = h (T - Ts)

Condensation Flux for a length L = h (T-Ts)/𝜆

Q =h AT

Dropwise and Filmwise condensation