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Condensation Heat Transfer
Dr Vishwas Wadekar
HTFS, Aspen Technology
Filmwise
Condensation
Overview of Four Lectures
• Lecture 1– Condensation - I
• Lecture 2– Condensation - II– Enhancement of heat transfer
• Lecture 3– Pool boiling heat transfer
– Flow patterns– Flow boiling heat transfer
• Lecture 4– Enhancement of boiling
Contents
� Modes of condensation
� Dropwise/filmwise condensation
� Direct/indirect/homogeneous condensation
� Filmwise condensation on
� Flat plate
� Outside/inside a tube
� Other complex effects
� Industrial equipment
Dropwise Filmwise
Condensation
Filmwise Condensation
� Condensed liquid forms a continuous liquid film on the heat transfer surface
� Examples of heat transfer surface can be
� Flat plate (as in the diagram)
� Outside/inside a tube
� Plate of a plate heat exchanger
� Heat transfer coefficient is lower (than dropwise mode) but predictable and stable
� Almost all industrial equipment is designed for this mode of condensation
Dropwise Condensation
� Condensed liquid forms droplets on the
heat transfer surface due to poor wettability
� Very high heat transfer coeff. (50-500 kW/m2K)! However, it can degrade to filmwise values over time
� This mode is promoted by
� Surface coating (e.g. with PTFE)
� Additives in vapour stream
� Still an area of ongoing research to make it work in industrial practice
Homogeneous Condensation
� Small droplets forming as fog
� Increase in pressure can lead to fog formation
� Droplets often too small to separate
� Fog and cloud formation are due to
homogeneous nucleation
� Undesirable in industrial practice
� Loss through venting system
� Possible source of pollution
Direct Contact Condensation
� Subcooled liquid is brought in contact with vapour
� Latent heat raises the temperature of subcooledliquid
� Efficient form of heat exchange
� Sea water desalination
� Power plants
� Emergency core cooling in nuclear reactors
Vapour
Liquid Spray
Vapour
Condensation
In the remaining lecture we now focus on indirect contact filmwise
condensation
Filmwise
Condensation
Resistances to Heat TransferPure vapour
+ non-condensable
vapour vapour+gas
Ti = Tsat
coolant coolantliquid
film
liquid
film
Tg
Ti
pv,b
pv,i
Pure vapour
General Approach to Condensation
� Filmwise condensation is considered
� Various geometries are covered
� Flat plate (vertical and inclined)
� Outside/inside a single tube
� Outside multiple tubes (tube bundle)
� Gravity controlled situations studied in detail
� Further complicating factors such as inundation and vapour shear effects are then examined briefly
General Approach to Condensation
Condensation on Flat Plate
�Nusselt analysed this case in 1916
� Analysis is considered in detail because -
� Milestone in condensation work
� Simplest geometry
� Forms the basis of other geometries
Nusselt Analysis -Assumptions
� Laminar condensate film� Gravitational and viscous forces only� Heat transfer by conduction through the film� Thermodynamic equilibrium at the interface� Uniform -
� Physical properties� Wall temperature
Nusselt Analysis - I
δ
Tsat
Tw
From film analysis
( )η
δρ−ρ=
3
3Wg
Vgl&
We define the mass flow rate per unit width as
( )η
δρ−ρρ=
ρ=Γ
3
3g
W
V glll&
Nusselt Analysis - II
Tsat
Tw
Liquid film flowrate, G, increases with distance, x. If Gc is condensation mass flux then from mass balance Gc = dΓ/ dx
( )dx
dg
dx
dG
gll
c
δδ
η
ρ−ρρ=
Γ= 2
33
dx
As ( )
η
δρ−ρρ=Γ
3
3ggll
Nusselt Analysis - III
Tsat
Tw
Condensation mass flux Gc is related to heat flux, , by (∆hv = latent heat of vaporisation)
( ) cvwsat
l GhTTq ∆=−δ
λ=&
Heat transfer through the film is by conduction. Therefore the heat transfer coefficient will be (λ l / δ)
cvGhq ∆=&cq&
δ
Combining….
( )dx
dgG
gll
c
δδ
η
ρ−ρρ= 2
( ) cvwsat
l GhTT ∆=−δ
λ
Condensation mass flux Gc and heat transfer equation
Condensation mass flux Gc and film flow equation
( )( ) vgll
wsatl
hg
dxTTd
∆ρ−ρρ
−ηλ=δδ3
On integrating…..
Local Coefficient
( )( ) vgll
wsatl
hg
xTT
∆ρ−ρρ
−ηλ=δ
44
….On integrating
δ
xLocal heat transfer coefficient
( )( )
4/13
4
−η
∆ρ−ρρλ=
δ
λ=α
xTT
hg
wsat
vgllll
Average Coefficient On integrating
OR
δ
x = L
( )( )
4/13
0943.0
1
−η
∆ρ−ρρλ=α=α ∫ LTT
hgdx
L wsat
vglllL
( ) η
Γ=
ρ−ρρ
η=
=λ
α= −
4Re;
Re47.1
3/12
3/1
gZ
whereZ
Nu
gll
l
Nusselt Analysis -Assumptions
�Laminar condensate film�Gravitational and viscous forces only�Heat transfer by conduction through the film�Thermodynamic equilibrium at the interface�Uniform -
� Physical properties� Wall temperature
Verification of NusseltAnalysis
� Earlier attempts to experimental verification were not successful because of
� Presence of non-condensible gases
� Presence of dropwise condensation
� Forced convective effects (vapour shear)
� Rippling, splashing and turbulence of the film
� Recent data under “Nusselt conditions” validates the simple Nusselt theory