CHENG 314 Heat Transfer

Dr. Zakir Hossain

E.mail: zhossain@uob.edu.bh
Office: 15-312
Tel: 17876374
Department of Chemical Engineering

University of Bahrain

1
 Chapter 10
Boiling and Condensation

2
 Phase Change

Vapor Liquid

Liquid vapor

3
 Condensation
Condensation means the change of phase from the vapor to the

liquid. If the temperature of a vapor is reduced below its

saturation temperature, condensation occurs.

In industrial equipment, the process commonly results from

contact between the vapor and a cool surface. The latent energy

of the vapor is released, heat is transferred to the surface, and

the condensate is formed.

4
 Modes of Condensation
Film condensation
-The condensate wets the surface and •
forms a liquid film.
-The surface is blanketed by a liquid •
film which serves as a resistance to
heat transfer.
Dropwise condensation
-The condensed vapor forms droplets •
on the surface.
-The droplets slide down when they •
reach a certain size.
-No liquid film to resist heat transfer •
-As a result, heat transfer rates that •
are more than 10 times larger than
with film condensation can be 5
5
achieved.
 Ts< Tsat

6
Modes of condensation: (a) film condensation, and (b) dropwise condensation
Homogeneous condensation

If a mixture of a vapor and gas is cooled, the vapor condenses to

form as droplets (or fog formation) suspended in the carrier gas.

Direct contact condensation

In contrast, if a vapor or a gas-vapor mixture comes in contact with

a cold Liquid

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Film Condensation

8
 Film Condensation
- Liquid film starts forming at the top of •
the plate and flows downward under the
influence of gravity.
•
- δ increases in the flow direction x •

-Heat in the amount hfg is released •

during condensation and is transferred
through the film to the plate surface.

-Ts must be below the saturation •

temperature for condensation. Ts< Tsat

-The temperature of the condensate is •

Tsat at the interface and decreases
gradually to Ts at the wall. 9
9
 Flow Regimes

The dimensionless parameter •

controlling the transition between
regimes is the Reynolds number
defined as:

Three prime flow regimes: •

Re < 30 ─ Laminar (wave-free) –
30 < Re < 1800 ─ Laminar (wavy) –
Re > 1800 ─ Turbulent –
The Reynolds number increases in •
the flow direction.

10
10
 Heat transfer in
condensation depends
on whether the
condensate flow is
laminar or turbulent.
The criterion for the
flow regime is provided
by the Reynolds
number.

11
11
 Empirical correlation-Laminar film condensation on
vertical surface

Nusselt Analysis: This analysis is based on the following major

assumptions:

12
Empirical correlation-Laminar film condensation on
vertical surface
3 1/ 4
h LL
 l g  l  v  hfg L 
Nu L   0.943  
kl  l kl Tsat  Ts  
or

13
 Empirical correlation-Laminar film condensation on
vertical surface

g = gravitational acceleration, m2/s

ρl , ρv = densities of the liquid and vapor,
respectively, kg/m3
µL = viscosity of the liquid, Pa.s
h’fg = Modified latent heat of vaporization, J/kg
KL = Thermal conductivity of the liquid, W/m K
L = height of the plate, m
Ts = Wall (surface) of the plate, oC.
Tsat = saturation temperature of the condensing
fluid, oC.

14
 h’fg = hfg (1 + 0.68 Ja) (2)

c p ,l  Tsat  Ts 
Jakob number, Ja  (3)
h fg

Ts  Tsat
All the properties are evaluated at Tf , Tf 
2

except ρv and hfg. These are evaluated at Tsat.

The total heat transfer to the surface is then

q  h A(Tsat  Ts ) (4)
15
The total condensation rate:

q h A (Tsat  Ts )
m  '  '
(5)
h fg h fg

and Film Reylonds number may be expressed as

4 m 4 l um  h ATsat  Ts 
N Re, f or N Re,   
l P l hfg l P (6)

P= wetted perimeter
16
 Effects of Turbulence•
Transition may occur in the film and three flow regimes may be identified
and delineated in terms of a Reynolds number defined as

4 4 m 4 l um
Re   
l l b l

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 Wave-free laminar region  Re  30  :

hL v / g 
1/ 3
2

Nu L   1.47 Re1/ 3
l
(10.38)
kl

Wavy laminar region  30  Re  1800  :

h L  vl2 / g 
1/ 3
Re
Nu L   (10.39)
kl 1.08 Re1.22  5.2

Turbulent region  Re  1800, Prl  1 :

h L  vl2 / g 
1/ 3
Re
Nu L  
8750  58 Prl 0.5  Re0.75  253
(10.40)
kl

Graphical representation of Equations 10.38; 10.39 and 10.40 with known δ is

shown in Fig 10.13 18
 Graphical representation of Equations 10.38; 10.39 and 10.40 with known δ

Fig: 10.13 Modified Nusselt number for condensation on vertical plate

The Reynolds number is based on the film thickness, δ, that exists at 

x = L. However, the film thickness, δ, is generally not known. 19
To facilitate their use, the preceding correlations can be rewritten in terms of
the dimensionless parameter, P, eliminating Re.
 k L T T 
P l
 sat s  
  h  v / g  
2
1/ 3 (10.42)
 l fg l 
Wave-free laminar region  P  15.8 :

hL v / g 
1/ 3
2

Nu L   0.943P 1/ 4
l
(10.43)
kl

Wavy laminar region 15.8  P  2530  :

h L  vl2 / g 
1/ 3
1
Nu L    0.68P  0.89 
0.82
(10.44)
kl P

Turbulent region  P  2530, Prl  1 :

h L  vl2 / g 
1/ 3
1
  0.024 P  53 Prl  89 
4/ 3
Nu L  1/ 2 (10.45)
kl P 20
 Film Condensation on Radial Systems

A single smooth tube or smooth sphere:•

1/ 4
h D  g l  l    hfg D3 
Nu D  D  C  
(10.46)
kl   k
l l  Tsat  Ts  
21
Tube: C = 0.729 Sphere: C = 0.826
 Film Condensation on Radial Systems

For tube bank the average coefficient over the tube array is:•

h D,N  hD N n

n = -1/6

N = number of vertical tier (row) tubes.

22
 Example

A vertical square plate, 0.15 by 0.15 m, is exposed to steam at

atmospheric pressure. The plate temperature is 98oC. Calculate
a) the heat transfer rate and b) mass of steam condensed per
hour.
Data supplied
at Tf (99oC) ρl= 960 kg/m3, μl = 2.82 ×10-4 Pa.s, kl = 0.68 W/m.K, Cpl=4216 J/Kg.K
at Tsat (100oC) and 1 atm pressure hfg = 2.255 X 106 J/kg, ρv= 0.598 kg/m3.
h’fg = hfg(1 + 0.68Ja) = 2260.734 kJ/Kg c p ,l  Tsat  Ts 
Ja 
h fg
Solve by two ways and compare your result
1) Assumption either laminar or turbulent 23
2) Using Dimensionless Parameter, P
 Example 10.3
The outer surface of vertical tube, which is 1 m long and has an outer diameter
of 80 mm, is exposed to saturated steam at atmospheric pressure and is
maintained at 50oC by the flow of cool water.

1) What is the rate of heat transfer by the coolant, and

2) What is the rate at which steam is condensate at the surface

24
 Example 10.4

A steam condenser consists of square array of 400 tubes, each 6

mm in diameter. The horizontal tubes are exposed to saturated
steam at a pressure of 0.15 bar and the tube surface
temperature is maintained at 25oC.

What is the rate at which steam is condensed per unit length of

tube?

25
Boiling

26
 BOILING HEAT TRANSFER
Evaporation occurs at the liquid–vapor interface •
when the vapor pressure is less than the saturation
pressure of the liquid at a given temperature.
Boiling occurs at the solid–liquid interface when a •
liquid is brought into contact with a surface
maintained at a temperature sufficiently above the
saturation temperature of the liquid.

27
27
Evaporation Vs Boiling
Evaporation Boiling
Occurs at all T Particular T

Vapor-liquid interface Solid- liquid interface

Occurs using Occurs using

internal energy external energy

Slow process Rapid process

28
 Classification of Boiling
1) Pool boiling •
- Boiling in the absence of bulk fluid •
flow.
- Any motion of the fluid is due to •
natural convection currents and the
motion of the bubbles under the
influence of buoyancy.

2) Flow boiling •
- Boiling in the presence of bulk •
fluid flow.
- In flow boiling, the fluid is forced •
to move in a heated pipe or over a
surface by external means such as
a pump. 29
3) Subcooled Boiling
-When the temperature of •
the main body of the liquid
is below the saturation
temperature.
- Bubbles formed at the
surface may condense in
the liquid

4) Saturated Boiling
-When the temperature of •
the liquid is equal to the
saturation temperature.
-Bubbles formed at the surface are
then propelled through the liquid by
buoyancy forces, eventually escaping
from a free surface
30
30
 Boiling Heat Flux

excess temperature

31
31
 The Boiling Curve qs  ΔTe

32
32
1) Free/Natural Convection Boiling  ΔT
e  5 C •

- Little vapor formation.

- Liquid motion is due principally to single-phase natural convection.

Onset of Nucleate Boiling - •ONB  ΔTe  5 C

33
 2) Nucleate Boiling ( A- C)

The bubbles form at an •

increasing rate at an increasing
number of nucleation sites as we
move along the boiling curve
toward point C.

Region A–B ─ isolated •

bubbles.

Region B–C ─ numerous •

continuous columns of
vapor in the liquid.

Onset
34
of Nucleate Boiling - •ONB  ΔTe  5 C 34
 Critical Heat Flux   ΔTe  30 C 
qmax

After point B the heat flux •

increases at a lower rate
with increasing Texcess, and
reaches a maximum at point
C.

The heat flux at this point is •

called the critical (or
maximum) heat flux.

35
3) Transition Boiling (C -D)
-When Texcess is increased past point •
C, the heat flux decreases.
-This is because a large fraction of the •
heater surface is covered by a vapor
film, which acts as an insulation.

- In the transition boiling •

regime, both nucleate and film
boiling partially occur.
- Operation in the transition •
boiling regime, which is also
called the unstable film boiling
regime, is avoided in practice.
-For water, transition boiling •
occurs over the excess
temperature range from about
30°C to about 120°C.

-Point D, where the heat flux reaches a 36

minimum is called the Leidenfrost point.
4) Film Boiling (beyond Point D)
- Beyond point D the heater •
surface is completely covered
by a continuous stable vapor
film.
-Point D, where the heat flux •
reaches a minimum is called the
Leidenfrost point.

-The presence of a vapor film •

between the heater surface and
the liquid is responsible for the
low heat transfer rates in the film
boiling region.
•
-The heat transfer rate •
increases with increasing
excess temperature due to
radiation to the liquid. 37
37
 Pool Boiling Correlations

Nucleate Boiling

- Rohsenow Correlation
3
 g  l  v    c p ,l Te 
1/2

qs  l h fg    n  (10.5)
    C s , f h fg Prl 
Cs , f , n  Surface/Fluid Combination (Table 10.1)

- Critical Heat Flux

 g  l   v  
1/ 4


qmax  Ch fg v   (10.6)
 v2 
C → surface geometry dependent

e.g. C = 0.149 for a large horizontal plate

= 0.131for large horizontal cylinder or sphere 38
Table 10.1: Values of Cs,f for Various Surface-
Fluid Combination

39
 Film Boiling
The cumulative (and coupled effects) of convection and radiation across
the vapor layer

h  hrad h 1/3
4/3 4/3
h conv
 
1/4
h conv D
 g    h D 3
 (10.8)
Nu D  C l v fg

kv  k  T
 v v s sat   T 
Geometry C
Cylinder(Hor.) 0.62
Sphere 0.67

40
40
Film Boiling

 T  T 4 4

h rad 
s sat

Ts  Tsat
 Ts4  Tsat4 
h rad 
s  Tsat ,
If h conv  Th rad

h  h conv  0.75 h rad

41
Example 10.1

42
Example 10.2

43
Acknowledgement

44