COLLEGE OF ENGINEERING

CHE486
FLUID AND THERMODYNAMICS LAB

SEMESTER 3, SESSION 2021/2022

TITLE:
FILM BOILING CONDENSATION

PREPARED BY:
STUDENTS’ NAME STUDENT ID
MUHAMMAD ARIFF HAIQAL BIN MUHAMAD TARMIZI 2020853792
MUHAMMAD AKIM BIN ISMAL 2020601678
FITRI AINA AQILAH BINTI MOHD SALLEHUDDIN 2020897376
NURUL HUSNINA BINTI SAIFOL BAHRI 2020449832

PREPARED FOR:
DR. SUHAIZA HANIM BINTI HANIPAH

SUBMISSION DATE:
27 JANUARY 2022
 TABLE OF CONTENTS

ABSTRACT...................................................................................................................... 2
INTRODUCTION ............................................................................................................ 3
THEORY.......................................................................................................................... 4
OBJECTIVES .................................................................................................................. 6
APPARATUS ................................................................................................................... 7
PROCEDURES ................................................................................................................ 8
RESULTS ......................................................................................................................... 9
SAMPLE CALCULATION ............................................................................................13
DISCUSSION ..................................................................................................................15
CONCLUSION................................................................................................................17
RECOMMENDATIONS .................................................................................................18
REFERENCES ................................................................................................................19
APPENDICES .................................................................................................................20

1
 ABSTRACT

In this experiment, we study the condensation process that takes place in both filmwise
and dropwise and we also calculated the heat flux and surface heat transfer coefficient for
filmwise and dropwise condensation. The main apparatus that we used in this experiment is a
designed condensers special for this kind of experiment. SOLTEQ Film & Dropwise
Condensation Unit (Model: HE163) was used to determine the heat flux and surface heat
transfer coefficient for filmwise and dropwise condensation. Condensation occurs when vapor
changes to liquid water when comes in contact with cold surface. Condensate that forms on
filmwise surface create a film of condensate that impede the transfer of heat due to gravitational
force. Condensate that forms on dropwise surface create a small liquid droplet one by one that
continuously direct the transfer of heat between vapor and cold surface. The liquid droplets
would grow in size and eventually flow to the bottom into the chamber. To calculate the heat
transfer coefficient, Nusselt equation are used. Nusselt says that the heat transfer that occurs
from the vapor through the film and to the wall is conduction. Therefore, the heat transfer
coefficients can be calculated. We need to obtain Tsat, Tsurf, Tin and Tout in this experiment.

2
 INTRODUCTION

The steam will condense on the cold surface when heat from the steam is transferred either
to the product or to the surrounding. The condensation of steam can take place in a few ways
which are dropwise and filmwise. For the same temperature difference between steam and the
surface, dropwise condensation is a lot more effective than filmwise.
In filmwise condensation, the surface over which the steam condenses is wet-able. Hence,
a film condensate is formed as the film condenses. This will result in lo w heat transfer rate as
the film condensate impedes the heat transfer.
However, for dropwise condensation, it takes place when the surface is not wet-able. The
droplets are formed when the steam condense. When the droplets become big, the automatically
fall under gravity. In dropwise condensation, heat transfer rate is achieved. Due to this many
chemicals are used to ensure that the condensation take place drop wise.
To help and understand about the key aspect in condensation in terms of the proce ss for
filmwise and dropwise, the SOLTEQ Film and Dropwise Condensation Unit (Model: HE163)
is designed to have a better understanding of the process. This allows students to visualized
both phenomena and perform a few experiments to demonstrate both of th e concept.

3
 THEORY

Condensation heat transfer is a vital process in Process and Power Generation industries.
Our understanding of the condensation process has gradually improved throughout the years.
Theories and models have become more accurate and are now applicable to a wider range of
conditions. There are two models of condensation, which are filmwise and dropwise
condensation.
Mechanism of condensation:
Condensation of vapor to a liquid and vaporization of a liquid to a vapor both involve a
change of phase of a fluid with large heat transfer coefficient. Condensations happens when a
saturated vapor such as steam comes in contact with a solid which surface temperature is below
the saturation temperature to form a liquid such as water.
A film of condensate is formed on the surface and flows over the surface by gravity when
the vapor condenses on a vertical or a horizontal tube or other surface. It is this film of liquid
between the surface and the vapor that forms the main resistance to heat transfer which is called
filmwise condensation.
Dropwise condensation occurs when a small drop is formed on the surface. The drops flow
and coalesce and the liquid flow from the surface. Large area of tubes is devoid of any liquid
and are exposed directly to the vapor during this condensation process. This causes high heat
transfer rate on these bare areas. The average heat transfer coefficient for dropwise
condensation is five to 10 times larger than the filmwise coefficients.
Dropwise condensation can be promoted by making the surface non -wetting. However
dropwise condensation is difficult to maintain in industrial applications due to oxidation,
fouling and degradation of coating, and eventually film condensation occurs. Theref ore,
condenser designs are often based on the assumption of filmwise condensation.
For film-type condensation on a vertical wall or tube can be analyze 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 and increases in thickness as its flows downward because of the
condensation. Nusselt assume that the heat-transfer from the condensation of the vapor, a final
expression can be obtained for the average heat-transfer coefficient over the whole surfaces.

Heat removes from the condensation: Q x = 𝒎̇ CΔT

Log mean temperature difference:

ΔTm

4
Heat flux:
Φ = qx

𝟒
Heat transfer coefficient:

U=

5
 OBJECTIVES

EXPERIMENT 1 - To demonstrate the filmwise and dropwise condensation

EXPERIMENT 2 - To determine the filmwise heat flux and surface heat transfer coefficient
at constant pressure

EXPERIMENT 3 - To determine the dropwise heat flux and surface heat transfer coefficient
at constant pressure

6
 APPARATUS

Figure 1: SOLTEQ Film & Dropwise Condensation Unit (Model: HE163)

7
 PROCEDURES

General Start-up Procedure

1. The main switch was turned on.
2. Valves V1 to V6 was checked to make sure it is closed.
3. The chamber was filled with distilled water until the water level stays between the
heater and baffle plates. The heater was ensured to fully immersed in the water
throughout the experiment. Water could be filled into the chamber through the drain
valve with the vent valve, V4 opened. Then, close the vent valve, V4.
4. The heater switch was turned on and power regulator was rotated to inc rease the
heating power.
5. Water was ensured to heat up until boiling point and the pressure was monitored to
reached and maintain between 1.02 -1.01 bar.
6. The system was let to stabilize. All the relevant measurements for the experimental
purpose were collected.

Experiment 2

1. Filmwise condenser was adjusted until minimum value of 0.1 LPM.

2. Power regulator was adjusted until it reaches the pressure 1.01 bar.
3. When the condition is stabilized, the steam (T sat) & surface temperature (Tsurf),
Tin(T1) and Tout(T2) and the flowrate was recorded.

Experiment 3

1. Filmwise condenser was adjusted until minimum value of 0.4 LPM.

2. Power regulator was adjusted until it reaches the pressure 1.01 bar.
3. When the condition is stabilized, the steam (T sat) & surface temperature (Tsurf),
Tin(T3) and Tout(T4) and the flowrate was recorded.

8
 RESULTS

EXPERIMENT 1:

1. Filmwise Condensation

Figure 2: Filmwise Condensation

2. Dropwise Condensation

Figure 3: Dropwise Condensation

TYPES OF CHARACTERISTIC OBSERVATION

CONDENSATION

9
FILMWISE Low rate of condensation There is a straight path for
water droplets to the bottom.

DROPWISE High rate of condensation The water drops move to the

bottom one by one.
Table 1: Result Experiment 1

EXPERIMENT 2: THE FILMWISE HEAT FLUX

Flowrate Power T in T T sat T surf Tsat – Tsurf ΔTm Φ U
(LPM) (W) (°C) out (°C) (°C) (°C) (W/m2) (W/m2
(°C) K)
0.1 306 32.5 76.3 70.8 95.4 -24.6 12.54 7155.66 570.63
0.3 1058 32.4 50.2 71.5 85.4 -13.9 29.30 8723.92 297.74
0.5 1058 32.3 44.8 71.6 80.7 -9.1 32.65 10210.6 312.73
0.7 1065 43.2 32.3 77.6 76.3 1.3 39.60 - -314.78
12465.22
Table 2: Result Experiment 2

Figure 4: Graph heat flux versus temperature difference for filmwise

10
Figure 5: Graph surface heat flux coefficient versus temperature difference for filmwise

EXPERIMENT 3: THE DROPWISE HEAT FLUX

Flowrate Power T in T out T T Tsat – Tsurf ΔTm Φ (W/m2) U
(LPM) (W) (°C) (°C) sat surf (°C) (W/m2K)
(°C) (°C)
0.4 951 31.8 76.3 87.3 71.5 15.8 27.49 2051100.06 7461.26
0.6 1136 31.8 50.2 88.8 71.5 17.3 47.20 1272165.9 26952.66
0.8 1267 21.6 44.8 86.6 71.5 15.1 52.55 2138670.4 40697.82
1 1261 31.8 42.9 83.7 71.5 12.2 46.13 1279053.3 27727.15
Table 3: Result Experiment 3

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 Figure 6: Graph heat flux versus temperature difference for dropwise

Figure 7: Graph surface heat transfer coefficient versus temperature difference for
dropwise

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 SAMPLE CALCULATION

Formula used:
1. Heat removes from the condensation, Qx = 𝒎̇CΔT

( 𝑻𝒔𝒂𝒕−𝑻𝒊𝒏) − (𝑻𝒔𝒂𝒕−𝑻𝒐𝒖𝒕)
2. Log mean temperature difference, ΔTm = 𝑻𝒔𝒂𝒕 − 𝑻𝒊𝒏
𝑰𝒏
𝑻𝒔𝒂𝒕 − 𝑻𝒐𝒖𝒕
𝑸𝒙
3. Heat flux, Φ = 𝝅𝒅𝟐
𝝅𝒅𝑳+
𝟒
𝜱
4. Heat transfer coefficient, U =
𝜟𝑻𝒎

Where
Diameter of the condenser, d=0.0127 m
Length of the condenser, L= 0.012 m
Specific heat capacity of water, C= 4186 J/m2K

CALCULATION FOR EXPERIMENT 2

[0.1 LPM]
( 𝑇𝑠𝑎𝑡−𝑇𝑖𝑛) – (𝑇𝑠𝑎𝑡−𝑇𝑜𝑢𝑡)
Find ΔTm = 𝑇𝑠𝑎𝑡 – 𝑇𝑖𝑛
𝐼𝑛
𝑇𝑠𝑎𝑡 – 𝑇𝑜𝑢𝑡

( 70.8−32.5) − (70.8−76.3)
= 70.8− 32.5 = 12.54
𝐼𝑛
70.8 − 76.3

Qx = 𝒎CΔT
= (0.1) (4186) (76.3-32.5)(1/60)
= 305.578

𝑸𝒙
Φ= 𝝅𝒅𝟐
𝝅𝒅𝑳+
𝟒

𝟑𝟎𝟓.𝟓𝟕𝟖
= 𝝅(𝟎.𝟎𝟏𝟐𝟕)𝟐 = 7155.66 W/m 2w
𝝅 ( 𝟎.𝟎𝟏𝟐𝟕)(𝟎.𝟎𝟏𝟐)+
𝟒

𝛷
U=
𝛥𝑇𝑚

13
 7155.66
=
12.54

= 570.63 W/m 2K
0.3LPM, 0.5LPM, 0.7LPM, and 0.4LPM, 0.6LPM, 0.8LPM, 1LPM in Experiment 3 are all
calculated the same way.
The same formula was used to figure out how much dropwise condensation would happen.

14
 DISCUSSION

The objective of this experiment is to demonstrate the filmwise and dropwise

condensation, to determine the heat flux and surface heat transfer coefficient at constant
pressure for each filmwise and dropwise. For experiment 1, we do the general setup and collect
the data respectively. In experiment 1, for fiilmwise condensation, the water flows directly to
the bottom of surface while on dropwise condensation, water droplets flow one drop by one
drop to the bottom. It is because filmwise at low-rate condensation while dropwise at high-rate
condensation.
After finished experiment 1, we do the experiment 2 to determine the filmwise heat flux
and surface heat transfer coefficient at constant pressure. In this experiment, we first circulate
the cooling water through the filmwise condenser starting with first value flow rate that is 0.1
LPM. Then we switch on the heater and adjust coarse to obtain the desired pressure that is 1.01
bar. When the condition is stabilized, we record the reading on T in(T1), Tout(T2), Tsat and Tsurf
Figure 4 display a graph that represents the heat flux for filmwise condensation. Based on the
data collected, we can calculate the heat flux and surface heat transfer with the formula stated.
Figure 5 shows a graph that represents the surface heat coefficient versus the temperature
difference. From these two graphs, we conclude that heat flux and surface heat transfer
coefficient increase with the temperature difference.
Next, for experiment 3 is to determine the dropwise heat flux and surface heat transfer
coefficient at constant pressure. We start the experiment by setting the minimum value of flow
rate that is 0.4 LPM. Then, we turn on the heater and adjust the coarse to obtain desired pressure
that is 1.01 bar. When the condition is stabilized, we record the reading on T in(T1), Tout(T2),
Tsat and Tsurf. After that, we calculate the heat flux and surface heat transfer coefficient for
dropwise condensation by using the data collected. Figure 6 shows the graph that represents
the heat flux for dropwise condensation while figure 7 shows the graph which represents the
surface heat transfer coefficient versus temperature difference. From these two graphs, we
conclude that heat flux and surface heat transfer coefficient increase with the temperature
difference. The line for both graphs that we get is not a straight line. There may be some errors
during the experiment. Maybe because the system condition is not fully stabilized yet when
taking the reading. We might be getting a slightly error data for these experiments because of
unfully stabilized system condition. To avoid this from happen again, we must wait a bit longer
and be more alert on the condition of the system so we can get an exact data.
For filmwise condensation, the process that takes place is vapour condensation when
vapour touch the cold surface of the filmwise. The droplets of water formed from condensation
wets the surfaces and flow directly to the bottom because of gravitational force. Filmwise
condensation form a layer of liquid water on its surfaces that might hinders the heat transfer
from vapour to cold surface. For dropwise condensation, the condensate does not form a layer
of liquid water as the condensate form a liquid droplet that grow in size and eventually flow
down to the bottom. Condensation takes place the most effectively on the dropwise
condensation as it forms liquid droplet not a film of water on the surface thus cold surface
remains continuously exposed to vapour for condensation to take places.

15
 At the end of the experiment, the equipment must be cooled down before draining the
water circulated inside the chamber. The tap water that we used must be free from any
contamination to prevent blockage from happening inside the condenser.

16
 CONCLUSION

In conclusion, dropwise condensation is more effective method for heat transfer between
vapour and cold surface than filmwise condensation. Heat flux for filmwise condensation for
0.1 LPM, 0.3 LPM, 0.5 LPM, 0.7 LPM are 7155.66 W/m2, 8723.92 W/m 2, 10210.6 W/m 2, and
-12465.22 W/m 2 respectively while heat flux for dropwise condensation for 0.4 LPM, 0.6 LPM,
0.8 LPM and 1 LPM are 2051100.06 W/m 2, 1272165.9 W/m 2, 2138670.4 W/m 2 and 1279053.3
W/m2 respectively. Surface heat transfer coefficient for filmwise condensation for 0.1 LPM,
0.3 LPM, 0.5 LPM, 0.7 LPM are 570.63 W/m2K, 297.74 W/m 2K, 312.73 W/m 2K and -314.78
W/m2K while for dropwise condensation for 0.4 LPM, 0.6 LPM, 0.8 LPM and 1 LPM are
7461.26 W/m 2K, 26952.66 W/m 2K, 40697.82 W/m 2K and 27727.15 W/m 2K respectively.
Objective of the experiment was obtained therefore the experiment was run successfully.

17
 RECOMMENDATIONS

Make sure to always opened the overflow valve to maintain or lower its pressure. Make
sure the valve is closely tight to ensure no leaking of water during the experiment. Other than
that, make sure the pressure switch to turn off the heater when the chamber pressure exceeds
1.20 abs bar, pressure relief valve to discharge at 1.5 abs bar.

18
 REFERENCES

1. Forbes Marshall: Steampedia: Dropwise and Filmwise condensation. Forbes Marshall

- Trusted Partners in Steam Engineering & Control Instrumentation. (n.d.).
Retrieved in January 25, 2022 from
https://www.forbesmarshall.com/Knowledge/SteamPedia/Basics/Dropwise-and-
Filmwise Condensation

2. Rose, J. W. (n.d.). Dropwise condensation. THERMOPEDIA. Retrieved January 25 ,

2022 from https://thermopedia.com/content/708/

3. Filmwise and Dropwise - SOLTEQ equipment for Engineering Education

Experimental Manual Film Dropwise Condensation Unit Model HE163 solution
engineering: Course hero. Filmwise and dropwise - SOLTEQ EQUIPMENT
FOR ENGINEERING EDUCATION EXPERIMENTAL MANUAL FILM
DROPWISE CONDENSATION UNIT MODEL HE163 SOLUTION
ENGINEERING| Course Hero. (n.d.). Retrieved
January 25, 2022, from https://www.coursehero.com/file/23091313/Filmwise-
and-dropwise/

4. Chapter 10: Boiling and Condensation. (n.d.). Retrieved on January 25, 2022 from
http://home.ku.edu.tr/~mmuradoglu/ME302/chapter_10.pdf

19
 APPENDICES

Figure 8: Filmwise condensation and dropwise condensation

Figure 9: Condensate form on filmwise and dropwise surface

20