1

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 T
sat
, T
surf
, T
in
and T
out
.


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.

2

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 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.
3


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.





















4

APPARATUS

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

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.
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.
6

2. The heater power is adjusted to obtain the desired pressure at 1.01 bar.
3. When the condition is stabilized, the steam (

) and surface temperature (

) ,

(T1) and

(T2), and flowrate are recorded.

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 (

) and surface temperature

(T3),

(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
7

Tsurf=31.0



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
Flowrate (LMP) Power (P)
Tin
( C)
Tout
( C)
Tsat
( C)
Tsurf
( C)
Tm
( C) q 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
8



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





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








0.00
500.00
1000.00
1500.00
2000.00
2500.00
30 35 40
H
e
a
t

f
l
u
x

Tsat-Tsurf
0.00
10.00
20.00
30.00
40.00
50.00
60.00
30 32 34 36 38 40
H
e
a
t

C
o
e
f
f
i
c
i
e
n
t

Tsat-Tsurf
Heat coefficient against Tsat-Tsurf
9


Experiment 3:

Table 2: The dropwise heat flux and surface heat transfer coefficient determination at constant pressure
Flowrate (LMP) Power (P)
Tin
( C)
Tout
( C)
Tsat
( C)
Tsurf
( C)
Tm
( C) q 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


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


0.00
5000.00
10000.00
15000.00
20000.00
25000.00
25.5 26 26.5 27 27.5 28
H
e
a
t

F
l
u
x

Tsat-Tsurf
Heat Flux vs. Tsat-Tsurf
0.00
100.00
200.00
300.00
400.00
500.00
600.00
25.5 26 26.5 27 27.5 28
H
e
a
t

C
o
e
f
f
i
c
i
e
n
t

Tsat-Tsurf
Heat Coefficient vs. Tsat-Tsurf
10

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



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


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









0.00
5000.00
10000.00
15000.00
20000.00
25000.00
25 30 35 40
H
e
a
t

F
l
u
x

Tsat-Tsurf
Heat Flux vs. Tsat-Tsurf
Dropwise
Filmwise
0.00
100.00
200.00
300.00
400.00
500.00
600.00
20 25 30 35 40
H
e
a
t

C
o
e
f
f
i
c
i
e
n
t

Tsat-Tsurf
Heat coefficient vs Tsat-Tsurf
Dropwise
Filmwise
11


Experiment 4:

Filmwise

Table 3: The effect of air inside chamber for filmwise
Flowrate (LMP) Power (P)
Tin
( C)
Tout
( C)
Tsat
( C)
Tsurf
( C)
Tm
( C) q 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



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

Table 4: The effect of air inside chamber for dropwise
Flowrate (LMP) Power (P)
Tin
( C)
Tout
( C)
Tsat
( C)
Tsurf
( C)
Tm
( C) q 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

0.000
50.000
100.000
150.000
200.000
250.000
300.000
34 35 36 37 38 39 40
H
e
a
t

C
o
e
f
f
i
c
i
e
n
t

Tsat-Tsurf
Heat coefficient vs Tsat-Tsurf
Heat
coefficient
12


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




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

0.00
100.00
200.00
300.00
400.00
500.00
600.00
700.00
38 38.5 39 39.5 40
H
e
a
t

C
o
e
f
f
i
c
i
e
n
t

Tsat-Tsurf
Heat coefficient vs Tsat-Tsurf
Heat
coefficient
0.00
50.00
100.00
150.00
200.00
250.00
300.00
34 35 36 37 38 39 40
H
e
a
t

c
o
e
f
f
i
c
i
e
n
t

Tsat-Tsurf
Heat coefficient vs Tsat-t surf for filmwise
without air
with air
13


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 ooccur, they didnt match for the desirable data.
0.00
100.00
200.00
300.00
400.00
500.00
600.00
700.00
20 25 30 35 40
H
e
a
t

c
o
e
f
f
i
c
i
e
n
t

Tsat-Tsurf
Heat coefficient vs Tsat-t surf for dropwise
without air
with air
14

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 condensationthe 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
15

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/














16