DROPWISE AND FILMWISE CONDENSATION APPARATUS

AIM:
To determine the inside and outside heat transfer coefficient of
Filmwise and Dropwise condenser.
To study the Dropwise and Filmwise condensation phenomena

APPARATUS:
Filmwise and Dropwise Condensers enclosed in a Borosilicate Glass
Tube with flow control valves, Steam generator with heating elements,
Digital Temperature Indicator with selector switch, Rotameter.

THEORY:

The processes involving phase change, like boiling and condensation,

are also very important in engineering practice. Boilers and condensers
are essential components of modern thermal power plants; so are the
evaporators and condensers in the vapor compression refrigeration
cycles. The phenomenon of boiling heat transfer has also been
successfully used in the cooling of nuclear reactors and rocket motors
where the energy dissipation rates are extremely large. In order to be

DROPWISE AND FILMWISE CONDENSATION

able to design these components effectively the phenomena of phase

change processes must be well understood.
The phenomena associated with boiling and condensation is much
more complex than the convection process. This is due to the fact that
latent heat effects, surface tension, surface characteristics and other
properties of two phase systems are very significant. High heat transfer
rates associated with small temperature differences are usually
involved in boiling and condensation.
Condensation Heat Transfer:

The process of condensation is the reverse of boiling. Whenever a

saturated vapor comes in contact with a surface at a lower
temperature,

condensation

occurs.

There

are

two

modes

of

condensation; filmwise, in which the condensate wets the surface

forming a continuous film which covers the entire surface and
dropwise in which the vapor
condenses into small liquid droplets of various sizes which fall down the
surface in a random fashion.
Filmwise condensation generally occurs on clean uncontaminated
surfaces. In this type of condensation the film covering the entire
surface grows in thickness as it moves down the surface by gravity.
There exists a thermal gradient in the film and so it acts as a resistance
to heat transfer. In dropwise condensation a large portion of the
DROPWISE AND FILMWISE CONDENSATION

area of the plate is directly exposed to the vapor, making heat transfer
rates much larger (5 to10 times) than those in filmwise.
condensation. Although dropwise condensation would be preferred to
filmwise condensation yet it is extremely difficult to achieve or
maintain. This is because most surfaces become wetted after being
exposed to condensing vapors over a period of time. Dropwise
condensation can be obtained under controlled conditions with the help
of certain additives to the condensate and various surface coatings but
its commercial viability has not yet been proved. For this reason the
condensing equipment in use is designed on the basis of filmwise
condensation.

APPARATUS DESCRIPTION:
DROPWISE AND FILMWISE CONDENSATION

The apparatus consist of:

Steam Generator: (8 liter capacity) equipped with 2 kW heater and
Pressure Gauge, Manual Release Valve, Feed Line and Steam Line.

Dropwise Condenser:

MOC:

Copper with chrome plating

Dimensions:

ID (di)

16 mm

OD (do)

19 mm

Length (L) 170 mm

Filmwise Condenser:

MOC:

Copper with Natural finish

Dimensions:

ID (di)
OD (do)

16 mm
19 mm

Length (L) 170 mm

Temperature Indicator with Selector Switch measures the Temperature
of :
T1

Steam Chamber Temp.

T2

Cooling Water In

T3

Filmwise Condenser Surface Temp

T4

Dropwise Condenser Surface Temp

T5

Cooling water outlet from film wise condensation surface

T6

Cooling water outlet from drop wise condensation surface

DROPWISE AND FILMWISE CONDENSATION

Rotameter (0.3-3.0 LPM) has been provided on the cooling water line to
measure the rate of water flowing through the condenser.
Ball valves have been provided to change the direction of cooling water
flow between either of the condensers.

EXPERIMENTAL PROCEDURE:

DROPWISE AND FILMWISE CONDENSATION

 Fill the steam generator with about 10 15 liter of water

(preferably soft).
Connect supply socket to the mains and switch on the heater.
Switch on the heater while keeping the steam line and feed line
valves in closed position.
Adjust the temperature of the steam near to the 105 110 OC.
Allow the steam generation to take place.
This may take 30 40 minutes depending on the initial
temperature of the feed water.
The pressure of the generated steam will be indicated on the
pressure gauge. Note down the Pressure reading of the steam
inlet.
Now select the condenser to be tested first and open the ball
valve of the same for cooling water supply.
Now start the supply of cooling water in the selected condenser
(Dropwise or Filmwise)
Depending upon the type of condenser under test Dropwise or
Filmwise condensation can be visualized.
If water flow rate is low than steam pressure in chamber will rise
and pressure gauge will read the pressure.

DROPWISE AND FILMWISE CONDENSATION

 If the water flow rate is matched than condensation will occur at

more or less at atmospheric pressure.
Process of Dropwise and Filmwise condensation can be easily
viewed through the front glass window of main unit.
Note down the inlet temperature of the cooling water, Outlet
Cooling water Temperature as indicated by the DTI.
Slowly open the steam line valve and allow the steam to enter the
steam chamber.
Observe the condensation phenomena and also note down the
condenser temperature, steam inlet temperature.
Measure and note the cooling water flow rate through Rotameter
provided.
Repeat the above procedure for the second type of condenser.
Use the wiper provided if the fog/ mist restricts the visualization
of the glass vessel.

DROPWISE AND FILMWISE CONDENSATION

PRECAUTIONS:
Do not start heater supply unless water is filled in the test unit.
Operate gently the selector switch of temperature indicator to
read various temperatures.
Increase the temperature gradually of the heater during initial
set-up experimentation.
Never use the heater at full wattage for longer period of
time.
Use the proper range of Rotameter.
Operate the change over switch of temperature indicator gently
from one position to other, i.e. from 1 to 4 positions.

DROPWISE AND FILMWISE CONDENSATION

OBSERVATIONS:
Filmwise Condensation:
Cooling Water Flow Rate (mw):

LPM

Temperature:
T

Steam Chamber Temp:

Cooling Water In:

Filmwise Condenser Surface Temp:

Cooling water outlet from film wise condensation surface

Dropwise Condensation:
Cooling Water Flow Rate (mw):

LPM

Temperature:
T

Steam Chamber Temp:

Cooling Water In:

Drop wise Condenser Surface Temp:

Cooling water outlet from drop wise condensation surface

DROPWISE AND FILMWISE CONDENSATION

CALCULATIONS:
Normally steam will not be pressurized, but the pressure gauge reads some
pressure than properties of steam should be taken at that pressure or
otherwise atmospheric pressure will be taken.

FIRST CALCULATE THE HEAT TRANSFER COEFFICIENT INSIDE THE

CONDENSER UNDER TEST.
For this properties of water are taken at bulk mean temperature of water
i.e. (Twi + Two) / 2.
Following properties are required:

Density of water kg / m3

Kinematic Viscosity m2/ sec

Thermal Conductivity k kcal / hr m C

Prandtl Number Pr

Reynolds Number NRe = v di /

Where
v (=mw*4/ * di2) = (Flowrate/Area)
di = Inner Diameter of Condenser

DROPWISE AND FILMWISE CONDENSATION

If this value of NRe > 2100 then flow is turbulent, below this value flow is
laminar.
Normally flow will be turbulent in the tube.

Nusselt Number NuD = 0.023 (ReD)0.4 (Pr)0.4

Inside heat transfer coefficient ( hi ) = NuD * k/ di

kcal / hr m2 C

CALCULATE HEAT TRANSFER COEFFICIENT ON OUTER SURFACE OF

THE CONDENSER HO:
For this properties of water are taken at bulk mean temperature of
condensate
(Ts + Tw) / 2.

Density of water kg / m3

Kinematic Viscosity m2/ sec

Thermal Conductivity k kcal / hr m C

Prandtl Number Pr

Reynolds Number NRe = v di /

Where, Ts Temperature of steam,

Tw Temperature of condenser wall
do outside diameter of condenser

ho = 0.725 * 2 * g * k3 / ( Ts - Tw) * do

DROPWISE AND FILMWISE CONDENSATION

From these values overall heat transfer coefficient (U) can be

calculated,
1/ U = 1 / hi + (di / do) (1 / ho)
U=

kcal / hr m2 C

The same procedure can be repeated for another condenser.

Except for some exceptional cases overall heat transfer coefficient for
dropwise condensation will be higher than that of filmwise condensation.
Results may vary from theory to some degree due to unavoidable heat losses
from the glass tube walls.

RESULT:

DROPWISE AND FILMWISE CONDENSATION

SAMPLE

CALCULATION:

First calculate the heat transfer coefficient inside the condenser under
test. For this properties of water are taken at bulk mean temperature of
water
i.e. (Twi + Two) / 2. Following properties are required:
PHYSICAL PROPERTIES AT WATER MEAN TEMPERATURE
Physical
Properties
Steam Pressure
Kg/cm2
Steam
Temperature OC
Mean
Temperature oC
Density of Water
kg/m3
Viscosity
Kg/ m s
Kinematics
Viscosity m2/ s
Cooling Water
Flowrate LPM
Vol. Flowrate
m3/s
Velocity
m/s
Thermal
Conductivity
kcal / hr m C
Specific Heat

Dropwise
Condenser

Filmwise
Condenser

1.5

1.5

Ts

99.3

99.4

Tm

35

35

993.95

993.95

0.00073

0.00073

0.732*10-6

0.732*10-6

0.000033

0.000033

0.164

0.164

0.537

0.537

CP

0.997

0.997

DROPWISE AND FILMWISE CONDENSATION

Reynolds Number
ReD

v di /

993.95*0.165*0.016/0.00073

3594

where
v

= Velocity of Cooling Water Inside Condenser, m/s

= mw*4 / * di2
where, mw

= vol. Flowrate, m3/s

= Q/ 60000
=2/60000
=0.00003333

= Coo

ling Water Flowrate, LPM

di

= Inner Diameter of Condenser, m

= Density of Water at mean Temperature, kg/m3

= Viscosity of Water at mean Temperature, kg/ms

If this value of ReD > 2100 then flow is turbulent, below this value flow
is laminar.
Normally flow will be turbulent in the tube.
Prandtl Number

DROPWISE AND FILMWISE CONDENSATION

NPr

Cp * / k

0.997*0.00073/0.537

4.878

Where
Cp

= Specific Heat of Water,

= Viscosity of Water, Kg/ m s

= Thermal Conductivity of Condenser Material, kcal/ hr

m OC
Nusselt Number
NuD =

0.023 (ReD)0.4 (Pr)0.4

0.023 * 35940.4 * 4.8780.4

1.1467

Thus Inside Heat Transfer Coefficient, kcal / hr m2 C

hi

NuD * k/ di

1.1467*0.537/0.016

38.48

kcal / hr m2 C

DROPWISE AND FILMWISE CONDENSATION

Normally steam will not be pressurised, but the pressure gauge reads
some pressure than properties of steam should be taken at that
pressure or otherwise atmospheric pressure will be taken.

Now

calculate the heat transfer coefficient outside the condenser under test.
For this properties of condensate are taken at bulk mean temperature
of Condenser wall and the Steam Inlet Temperature
i.e. (Tw + Ts) / 2. Following properties are required:

DROPWISE AND FILMWISE CONDENSATION

PHYSICAL PROPERTIES AT CONDENSATE MEAN TEMPERATURE

Physical
Properties
Steam Pressure
Kg/cm2
Steam
Temperature OC
Mean Tamp
0
C
Density of Water
kg/m3
Viscosity
Kg/ m s
Kinematics
Viscosity m2/ s
Cooling Water
Flowrate LPM
Vol. Flowrate
m3/s
Velocity
m/s
Thermal
Conductivity
kcal / hr m C
Specific Heat

Dropwise
Condenser

Filmwise
Condenser

1.5

1.5

Ts

99.3

99.4

Tm

78.45

82.2

971.8

971.8

0.000355

0.000355

0.365*10-6

0.365*10-6

0.000033

0.164

0.579

CP

0.997

DROPWISE AND FILMWISE CONDENSATION

Calculate heat transfer coefficient on outer surface of the condenser h o.

Where, Ts Temperature of steam, Tw Temperature of condenser wall

ho

0.725 * 2 * g * k3 / ( Ts - Tw) * do

0.725*2*9.81*0.579 3 /(99.3-78)*0.019

6.605

kcal / hr m2 C

From these values overall heat transfer coefficient (U) can be

calculated,

1/ U =
=

1 / hi + (di / do) (1 / ho)

1/38.48 +(16/19)(1/6.605)
=

0.1534

Thus,
U

kcal / hr m2 C

6.5188

The same procedure can be repeated for another condenser.

Except for some exceptional cases overall heat transfer coefficient for
Dropwise

condensation

will

be

higher

than

DROPWISE AND FILMWISE CONDENSATION

that

of

Filmwise

condensation. Results may vary from theory to some degree due to

unavoidable heat losses from the glass tube walls.
SR.NO

ITEM NAME

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.

Nipple

Elbow
Union
Ball valve
Gate valve
Coupling
Elbow (L-

14.
15.

type)
Glass tube
Glass
(Distance

16.

piece )
Metal flange

SIZE

9
24
2
3
6
9

MATERIAL
USED
GI
GI
GI
GI
GI
GI
Copper

QTY.
3
4
1
3
1
2
1
3
1
7
1
3
2
1

200 150
(6 )
6

DROPWISE AND FILMWISE CONDENSATION

WATER
T1
T
T
DROPWISE
CONDENSOR
2
4
T3 STEAM
DROPWISE FILMWISE CONDENSATION
APPARATUS
INLET
MOC: COPPER WITH Cr.PLATING
INLET
DI = 160 mm
DO = 190 mm
FILMWISE
CONDENSOR
L = 170 mm
MOC: COPPER WITH NATURAL FINISH
DI = 160 mm
DO = 190 mm
L = 170 mm

DROPWISE AND FILMWISE CONDENSATION