ABSTRACT

This Film and Dropwise Condensation Unit is used to observe the process of heat

transfer during condensation, as well as gather experimental data for a better theoretical

understanding. The unit itself contained bench top unit, with an integrated steam generator

and air extraction system. The main components in the unit are the specially designed

condensers for the observation of both filmwise and dropwise condensation about the

differences of them. In this experiment, we want to study the heat transfer coefficient and

the heat flux. Besides that, we were study the effect of air inside the chamber. Condensation

occurs when vapour 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 using Nussselt equation. .

Nusselt assumed that the heat transfer that occurs from the vapour through the film and to

the wall is conduction. Since the process is conduction is well known, therefore calculation

on the heat-transfer coefficients can be done. In this experiment, obtained data are for Tsat,

Tsurf, Tin and Tout.

THEORY

Mechanism of Condensation

Condensation of a vapor to a liquid and vice versa, both involve a change of a fluid with

large heat-transfer coefficients. Condensation occurs when a saturated vapor such as steam

makes a contact with a solid whose surface temperature is below the saturation temperature, to

form a liquid such as water.

When a vapor condenses on a surface, for example vertical or horizontal tube or other

surface, a film of condensate is formed on the surface and flows over the surface because of

gravity. It is this film of liquid between the surface and the vapor that produce the main

resistance of heat transfer. This is called filmwise condensation.

Another type of condensation is dropwise condensation. Dropwise condensation occurs

when small drops are formed on the surface. These drops grow and mix together, and the liquid

flows from the surface. Large areas of tube are devoid of any liquid and are exposed directly to

the vapor during condensation. Very high rates of heat-transfer occur on these bare areas. The

average heat transfer coefficient for dropwise condensation is five to ten times larger than the

filmwise coefficient.

Dropwise condensation can be promoted by making the surface non-welting by coating.

However, dropwise condensation is difficult to maintain in industrial applications because of

oxidation, fouling and degrading of coating, and finally 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 find 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. It increases in thickness as it flows downward as a result of condensation. Nusselt

assumed that the heat transfer from the condensing vapor at Tsat, through this liquid film, and at

the wall at Tw, was by conduction. Equating this heat-transfer by conduction to that from

condensation of the vapor, final expression can be obtained for the average heat-transfer

coefficient over the whole surfaces.

PROCEDURE

Experiment 1: Demonstration of Filmwise and Dropwise Condensation

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

2. The power was set to minimum by turned power regulation knob to fully anticlockwise.

3. Valves V1 to V6 checked to ensure they were closed.

4. The chamber filled with distilled water until the heater immersed and water level in

between heater and baffle plates. Water filled into the chamber through the V1.
5. The water flow rate to condenser adjusted by controlling the control valve according to the

experimental procedure.

6. The main switch and heater switch were turned on. Heater power set by rotating the

regulation power anticlockwise to increase the heating power.

7. The water temperature reading observed.

8. The water was heated to boiling point until the pressure reached 1.02 1.10 bar. Valve V1

and valve V5 opened for 1 minute to vacuum out the air inside the condenser. Then both

valves were closed.

9. All relevant measurements for experimental purposes noted after the system stabilized.

Experiment 2: The Filmwise Heat Flux and Surface Heat Transfer Coefficient

Determination at Constant Pressure

1. Cooling water circulated through the filmwise condenser starting with a minimum value of

0.10 LPM.

2. Heater power adjusted to obtain the desired pressure at 1.01 bar.

3. The steam (Tsat) and surface temperature (Tsurf), Tin (T1) and Tout (T2), and flowrate

recorded when the condition stabilized.

Experiment 3: The Dropwise Heat Flux and Surface Heat Transfer Coefficient

Determination at Constant Pressure

1. Cooling water circulated through the dropwise condenser starting with a minimum value of

0.4 LPM.
2. Heater power adjusted to obtain the desired pressure at 1.01 bar.

3. The steam (Tsat) and surface temperature (Tsurf), Tin (T3) and Tout (T4), and flowrate

recorded when the condition stabilized.

Experiment 4: The Effect of Air inside the Chamber

1. Cooling water circulated through the filmwise condenser at the highest flowrate until the

pressure is reduced to below 1 bar.

2. The discharge valve opened to let an amount of air to enter the chamber.

3. Water flow to the condenser regulated starting with a minimum value of 0.4 LPM.

4. Heater power adjusted to obtain the desired pressure at 1.01 bar.

5. The steam (Tsat) and surface temperature (Tsurf), Tin (T3) and Tout (T4), and flowrate

recorded when the condition stabilized.

6. Steps 1 6 repeated for dropwise condensation.