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.

INTRODUCTION

Filmwise and Dropwise are two forms of condensation. In filmwise condensation a laminar film of
vapour is created upon a surface. This film can then flow downwards, increasing in thickness as additional
vapour is picked up along the way. In dropwise then flow downwards, accumulating static droplets below
them along the way.

When the rate of condensation is low (e.g., a noncondensible gas is present) or when the liquid
does not "wet" the wall, dropwise condensation occurs. In most engineering components where
condensation is a required part of an industrial process film condensation is expected, because of the large
mass flux of condensed liquid per unit length of wetted area.

Dropwise condensation was first recognized by Schmidt et al. (1930), and much interest was
stimulated by their report that heat transfer coefficient were between 5 and 7 times those found with film
condensation. Over the years there have been a few demonstrations of successful applications on an
industrial scale. This experiment would be used in by any industry which is trying to increase the efficiency
of heat transfer. An example of this is any vapour power cycle such as the rankine cycle. By increasing the
efficiency of the condenser, its operational pressure can be reduced and the overall efficiency of the cycle
can be increased. Dropwise condensation is difficult to sustain reliably; therefore, industrial equipment is
normally designed to operate in filmwise condensation mode.

In all application, the steam must be condensed as it transfer heat to a cooling medium which could
be cold water in a condenser of generating station, hot water in a heating calorifier, sugar solution in a

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sugar refinery and etc. during condensation very 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.

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 and how their applied and give benefit in industry.

OBJECTIVES
1. To demonstrate the filmwise and dropwise condensation.
2. To describe filmwise and dropwise condensation
3. To demonstrate the effect of air on heat transfer coefficient of condensation
4. To demonstrate the filmwise heat flux and surface heat transfer coefficient ay constant pressure.
5. To determine the dropwise heat flux and surface heat transfer coefficient at constant pressure.

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

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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.

APPARATUS

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Equipment Prefer:
SOLTEQ MODEL: HE 163 (Film and Dropwise Condensation Unit)

PROCEDURE

General Start-up
1. The main switch is ensured in its off position.
2. The power regulator knobs are turned fully anti-clockwise to set the power to minimum.
3. Valves V1 to V6 are checked to ensure its closed.
4. The chamber is filled with distilled water until the water level stays between the hater and baffles
plates. The heater is ensured fully immersed in the water throughout the experiment. The chamber
is filled with water through the drain valve with the vent valve, V4 opened. Then the vent valve V4
is closed.
5. The water flow rate to the condenser is adjusted by controlling the control valve according to
experimental procedure.
6. The main switch and the heater switch are turned on. The heater power is set by rotating the power
regulator clockwise to increase the hater power.

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 7. The water temperature reading is observed where the water temperature should increase when
its start heat-up.
8. The water is heated up to boiling point until the pressure reaches 1.02-1.10 bar. Immediately valve
V1 is opened and follow by valve V5 for 1 minute to vacuum out the air inside condenser. Then
both valve V1 and V5 is closed.
9. The system is let to stabilize. Then all relevant measurement is taken for experimental purposes.
Adjustment is made if required.

General shut-down
1. The voltage control knob is turned to 0 Volt position by turning the knob fully anti-clockwise. The
cooling water is kept flowing for at least 5 minutes through the condenser to cold them down.
2. The main switch and power supply are switch off. Then, the power supply cable is unplugged.
3. The water supply is closed and the cooling water connection tubes are disconnected if necessary.
Otherwise, the connection tubes are leaved for next experiment.
4. The water inside the chamber is discharged using the discharge valve.

A) Demonstration of filmwise and dropwise condensation

1. The basic procedure is followed as written in the general set-up. The equipment by make sure
connected to the service unit.

B) The filmwise heat flux and surface heat transfer coefficient determination at constant
Pressure

1. Cooling water is circulated through the filmwise condenser starting with a minimum value of 0.1
LPM.
2. The heater power is adjusted to obtain the desired pressure at 1.01 bar.
3. When the condition is stabilized, the steam (Tsat ) and surface temperature (Tsurf) , Tin (T1) and
Tout (T2), and flowrate are recorded.

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C) The dropwise heat flux and surface heat transfer coefficient determination at
Constant pressure

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

RESULTS

Experiment 1: Demonstration of filmwise and dropwise condensation

Pressure is kept constant at 1.02-1.10 bar

Tin= 30.2
Tout=29.7
Tsat=61.8
Tsurf=31.0

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 Figure 2: (Left) The Filmwise Condensation and (right) The Dropwise Condensation

Experiment 2:

Table 1: The filmwise heat flux and surface heat transfer coefficient determination at constant pressure
Tin Tout Tsat Tsurf ΔTm
Flowrate (LMP) Power (P) (̊ C) (̊ C) (̊ C) (̊ C) (̊ C) q ɸ U
0.1 185 31.9 32 66.9 30.7 34.95 0.70 172.82 4.94
0.2 205 34.3 34.6 70.4 33.3 35.95 4.19 1036.91 28.84
0.3 230 34.6 34.9 70.8 34.1 36.05 6.28 1555.36 43.14
0.4 259 34.7 34.9 71.6 33.8 36.80 5.58 1382.54 37.57
0.5 269 34.6 34.8 70.8 34 36.10 6.98 1728.18 47.87
0.6 274 34.7 34.9 71.4 33.8 36.60 8.37 2073.82 56.66

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 2500.00

2000.00

1500.00
Heat flux

1000.00

500.00

0.00
30 35 40
Tsat-Tsurf

Graph 1: Heat Flux vs. Tsat-Tsurf for filmwise without air

Heat coefficient against Tsat-Tsurf

60.00

50.00
Heat Coefficient

40.00

30.00

20.00

10.00

0.00
30 32 34 36 38 40
Tsat-Tsurf

Graph 2: Heat coefficient against Tsat-Tsurf for filmwise without air

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Experiment 3:

Table 2: The dropwise heat flux and surface heat transfer coefficient determination at constant pressure
Tin Tout Tsat Tsurf ΔTm
Flowrate (LMP) Power (P) (̊ C) (̊ C) (̊ C) (̊ C) (̊ C) q ɸ U
0.4 347 34.6 35.7 68.8 41.6 33.65 30.70 7605.52 226.04
0.6 365 34.4 35.2 71.4 44.2 36.60 33.49 8296.93 226.70
0.8 487 34.9 35.9 72.2 44.6 36.80 55.82 13828.21 375.79
1 562 34.4 35.2 72 45 37.20 55.82 13828.21 371.74
1.2 588 35.1 35.9 71.8 45.2 36.30 66.99 16593.86 457.15
1.4 623 34.4 35.2 71.6 45.7 36.80 78.15 19359.50 526.09

Heat Flux vs. Tsat-Tsurf

25000.00

20000.00
Heat Flux

15000.00

10000.00

5000.00

0.00
25.5 26 26.5 27 27.5 28
Tsat-Tsurf

Graph 3: Heat Flux vs. Tsat-Tsurf for dropwise without air

Heat Coefficient vs. Tsat-Tsurf

600.00

500.00
Heat Coefficient

400.00

300.00

200.00

100.00

0.00
25.5 26 26.5 27 27.5 28
Tsat-Tsurf

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 Graph 4: Heat coefficient against Tsat-Tsurf for dropwise without air

Heat Flux vs. Tsat-Tsurf

25000.00

20000.00
Heat Flux

15000.00

Dropwise
10000.00
Filmwise
5000.00

0.00
25 30 35 40
Tsat-Tsurf

Graph 5: The comparison of heat flux vs Tsat-Tsurf for dropwise and filmwise in the absence of air

Heat coefficient vs Tsat-Tsurf

600.00

500.00
Heat Coefficient

400.00

300.00
Dropwise
200.00 Filmwise
100.00

0.00
20 25 30 35 40
Tsat-Tsurf

Graph 6: The comparison of heat coefficient vs Tsat-Tsurf for dropwise and filmwise in the absence of air

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Experiment 4:

Filmwise

Table 3: The effect of air inside chamber for filmwise

Tin Tout Tsat Tsurf ΔTm
Flowrate (LMP) Power (P) (̊ C) (̊ C) (̊ C) (̊ C) (̊ C) q ɸ U
0.1 248 33.1 35.1 68.3 33.7 34.19 13.96 3457.05 101.112
0.2 275 33.1 33.6 69.9 32.5 36.55 6.98 1728.53 47.293
0.3 298 33.1 34.9 69.7 33.9 35.69 37.68 9334.04 261.513
0.4 308 33.3 33.4 69.8 32.1 36.45 2.79 691.41 18.969
0.5 326 33.3 33.4 69 32.1 35.65 3.49 864.26 24.243
0.6 339 33.4 33.5 70.9 32.1 37.45 4.19 1037.12 27.693

Heat coefficient vs Tsat-Tsurf

300.000

250.000
Heat Coefficient

200.000

150.000

100.000 Heat
coefficient
50.000

0.000
34 35 36 37 38 39 40
Tsat-Tsurf

Graph 7: The heat coefficient vs Tsat-Tsurf for filmwise with 1% air

Dropwise

Table 4: The effect of air inside chamber for dropwise

Tin Tout Tsat Tsurf ΔTm
Flowrate (LMP) Power (P) (̊ C) (̊ C) (̊ C) (̊ C) (̊ C) q ɸ U
0.4 351 33.4 34.3 71.3 32.6 37.45 25.12 6222.70 166.17
0.6 499 33.4 34.4 70.5 32.4 36.60 41.87 10371.16 283.38
0.8 599 33.6 34.4 71.2 32.6 37.20 44.66 11062.57 297.39
1 383 33.6 34.5 71.4 32.7 37.35 62.80 15556.74 416.53
1.2 571 33.8 34.7 72.8 32.9 38.55 75.36 18668.09 484.28
1.4 665 34 34.9 71.7 33 37.25 87.92 21779.44 584.71

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 Heat coefficient vs Tsat-Tsurf
700.00
600.00
Heat Coefficient 500.00
400.00
300.00
Heat
200.00 coefficient
100.00
0.00
38 38.5 39 39.5 40
Tsat-Tsurf

Graph 8: The heat coefficient vs Tsat-Tsurf for dropwise with 1% air

Heat coefficient vs Tsat-t surf for filmwise

300.00

250.00
Heat coefficient

200.00

150.00
without air
100.00 with air
50.00

0.00
34 35 36 37 38 39 40
Tsat-Tsurf

Graph 9: The heat coefficient vs Tsat-Tsurf for filmwise with and without 1% of air

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 Heat coefficient vs Tsat-t surf for dropwise
700.00
600.00

Heat coefficient 500.00

400.00
300.00 without air

200.00 with air

100.00
0.00
20 25 30 35 40
Tsat-Tsurf

Graph 10: The heat coefficient vs Tsat-Tsurf for dropwise with and without 1% of air

DISCUSSIONS

In this experiment we are mostly investigate about the film boiling condensation by using
the SOLTEQ Film and Dropwise Condensation Unit (Model: HE 163). There are 4 objectives that must be
accomplished. For the experiment 1, we have to demonstrate the filmwise and dropwise condensation.
From this experiment, we are able to describe the characteristics of filmwise and dropwise condensation.
In filmwise condensation, most materials used in the construction of heat exchangers are “wettable” and
during the condensation a film condensate spreads over the surface. More vapour condenses onto the
outside of this film will increases its thickness and causes the flow downward and drip from the lowest
points. The heat given up by the vapour during condensation is conducted through the film. During filmwise
condensation a layer of condensate covers the cool surface and this will causes the resistance to the
transfer of heat. However, for the dropwise condensation the material used in the construction is “non-
wet table” .When the steam condenses, a large number of spherical forms on its surface. These beads
become larger and then the 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.

For experiment 2 and 3, theoretically there is a big difference from the graph for the dropwise and
filmwise condensation based on its heat transfer coefficient and temperature difference. For dropwise
there is a relatively larger area heat transfer coefficient that proposes a larger value of heat transfer during
condensation. As for filmwise there is a smaller value of heat transfer and the larger area on the graph that
shows the larger margin of heat transfer value are at larger heat transfer value. But for the errors that has
occur, they didn’t match for the desirable data.

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 For experiment 4, theoretically, the clear difference between both heat transfer coefficient and
temperature difference for filmwise and dropwise condensation is for dropwise with the present of air
there is a larger value of heat transfer coefficient at a small temperature difference rather than for filmwise
that shows a smaller value of heat transfer coefficient and at a more larger difference of temperature. The
analysis for the data collected is that heat flux shows a clear difference due to the presence of air. With the
presence of air the heat flux value is smaller. Dropwise condensation is far more efficient for condensation
process due to the specifications for each plate surface. However we are not able to achieve the desired
outcome due to some errors.

The errors involve that effect the results is due to fluid involve for the process of condensation to occur.
The impurities that contain within the fluid involve has effect the density and boiling temperature that
occur at a much lower temperature. Thus condensation occurs at a less precise order and resulting in
impairment data.

CONCLUSION

For experiment 2 and 3, we have concluded that the dropwise condensation heat flux and surface
heat transfer coefficient at constant pressure occur at a relatively larger value at smaller temperature
difference than for filmwise condensation. Thus efficient condensation

For experiment 4, we have demonstrate the effect of air on heat transfer coefficient of
condensation for dropwise and filmwise, it concluded that dropwise has a more stable and larger heat
transfer value for condensation process thus a more efficient condensation process.

RECOMMENDATIONS
1. Avoid error in taking readings and make sure eyes of observer are parallel to the meniscus
2. Make sure the valve are close tightly when the film condensation equipment is turn off.
3. Make sure all the valve close at the beginning of the experiment
4. Allow the cooling water to flow at the end of the experiment before the equipment is shut down to
avoid the cracking of cylindrical tube.

REFERENCES

1) Aksan, S. N. and Rose, J. W. (1973). Dropwise condensation—the effect of thermal properties of

the condenser material. Int. J. Heat Mass Transfer, 16, 461-467.
2) Blackman, L. C. F., Dewar, M. S. J. and Hampson, H. (1957). Compounds for promoting dropwise
condensation of steam. J. Appl. Chem., 7, 160-171.

Date of search: 27/5/2013

 http://www.freepatentsonline.com/5048600.html

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  http://www.p-a-hilton.co.uk/English/Products/Heat_Transfer/heat_transfer.html
 http://wins.engr.wisc.edu/teaching/mpfBook/node9.html

Date of search: 30/5/2013

 http://www.focus-science.com/pahilton-heattransfer-h910.html
 http://www.springerlink.com/content/46322536602154p1/
 http://www.scribd.com/doc/22992765/Dropwise-and-Fimwise-Condensation-Lab-Report
 http://www.husni.net/Labs/Files/HeatTransfer/Exp6.pdf
 http://www.springerlink.com/content/u2882206203n3788/

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