Condensation Heat Transfer

ChE 301
Condensation: Phase change phenomena

Application of condensation process:

Heat Transfer 1) Distillation column: In mass transfer operation where vapor is
condensed at the top of the column.
Instructor: 2) Reactor: Product is condensed from the high temperature reaction
3) Heat exchanger: boiling or heating of a liquid by steam heating
Dr. Md. Easir Arafat Khan
Associate Professor Condensation
Department of Chemical Engineering, BUET,
Dhaka-1000
Homogeneous Surface
Condensation Condensation
January, 2021

Film Dropwise
Condensation Condensation
1 2

Condensation Heat Transfer Condensation Heat Transfer

Condensation occurs when the temperature of a vapor is reduced below
Film condensation
its saturation temperature.
Film condensation Liquid film starts forming at the top of
The condensate wets the surface and the plate and flows downward under
forms a liquid film. the influence of gravity.
The surface is blanketed by a liquid increases in the flow direction x
film which serves as a resistance to Heat in the amount hfg is released
heat transfer. during condensation and is transferred
through the film to the plate surface.
Dropwise condensation
Ts must be below the saturation
The condensed vapor forms droplets temperature for condensation.
on the surface.
The temperature of the condensate is
The droplets slide down when they Tsat at the interface and decreases
reach a certain size. gradually to Ts at the wall.
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 achieved. 3 4
 Condensation Heat Transfer Condensation Heat Transfer
From the Newton' s second law of motion,
1 Vertical Plates Fx ma x 0
Assumptions: since the acceleration of the fluid is zero. The acting force
1. Both the plate and the vapor are maintained at on the fluid element is
constant temperatures of Ts and Tsat, Fdownward Fupward
respectively, and the temperature across the weight viscous shear force bouyancy force
liquid film varies linearly.
du
2. Heat transfer across the liquid film is by pure g - y bdx bdx vg - y bdx
dy
conduction.
du g -y
3. The velocity of the vapor is low (or zero) so that it v

exerts no drag on the condensate (no viscous dy

shear on the liquid vapor interface). Integrating,
4. The flow of the condensate is laminar (Re<30) g g
u v
y v
y 2 C1
and the properties of the liquid are constant. 2
5. The acceleration of the condensate layer is Since, y 0, u 0, then interation constant C1 0.
negligible.
g v y2
u y (1)
5 2 6

Condensation Heat Transfer Condensation Heat Transfer

The mass flow rate of the condensate at a location x, where boundary layer Equating equation (2) and (3),
thickness 2
b g v d T Ts
g 2
y bk sat
mx u bdy b v
y dy dx
0 0 2 k Tsat T s
3
d dx
b g v y2 y3 b g v
3
g v
2 6 0
3 x k Tsat Ts 4
kx Tsat Ts
3
Integrating , d dx
The differential mass flow rate is then, 0 0 g v 4 g v
2
dm b g d 1/ 4
v
(2) 4 kx Tsat Ts
dx dx (4)
g v
Which represent the rate of condensation of vapor over a vertical distance dx,
Now, local heat transfer coefficient h x can be expressed as,
The rate of heat transfer from the vapor to the plate through the liquid film is
equal to the heat released as vapor condensed and is epressed by
heat flux at x qx 1 k Tsat Ts k
hx
T Ts
T Tsat Ts Tsat Ts
dQ m k bdx sat 1/ 4
gk 3
Tsat Ts
Therefore, h x v
(5)
dm 4 Tsat Ts x
bk (3)
dx
7 8
 Condensation Heat Transfer
Film Reynolds Number:
The average heat transfer coefficient, h is determined as The Film Reynolds number may be expressed as
1/ 4 3
1 L 1 gk 3 L Dh u 4A u 4m b g v
h hx dx v
x 1/ 4
dx Re where, m
L 0 L 4 Tsat Ts 0 p b 3
3
1/ 4 4 g
4 gk 3 v
v
3 2
3 4 Tsat Ts L
1/ 4
Assuming, v , the average heat transfer coefficient relationship can be
gk 3 v expressed in terms of modified nusselt number,
0.943
Tsat Ts L 2 3 3
4 g 4g
where, all liquid properties should be evaluated at the film temperature Re 2 2
3 3
The total heat transfer to the surface can be obtained by 1/ 3
4 4k 4k 4g
q h A(Tsat Ts ) Now, h hx
3 3 3 3 2 Re
The total condensation rate may then be obtained from the relation 1/ 3
2
h /g 1/ 3
q h A(Tsat Ts ) 1.47 Re for Re 30
m k

9 10

Condensation Condensation Heat Transfer

Problem: Flow Regimes
A vertical square plate, 30 by 30 cm, is exposed to saturated steam at
atmospheric pressure and the plate temperature is maintained at 980C. The dimensionless parameter controlling
Calculate the heat transfer and the mass of steam is condensed per hour. the transition between regimes is the
The average heat transfer coefficient, h is determined as Reynolds number defined as:
1/ 4
gk 3 v
h 0.943
Tsat Tw L
Three prime flow regimes:
The rate of heat transfer
Re < 30 Laminar (wave-free)
q h A(Tsat Tw ) 30 < Re < 1800 Laminar (wavy)
Total condensation rate can then be obtained from the relation Re > 1800 Turbulent
q h A(Tsat Tw ) The Reynolds number increases in the
m
flow direction.
Renolds number
4m 4h L(Tsat Tw )
Re
b
11 12
 Inclined Plates
Film Reynolds Number:
Equation 10 22 was developed for vertical plates,
but it can also be used for laminar film condensation
In laminar wavy region, Kutateladze recommends a correlation,
on the upper surfaces of plates that are inclined
1/ 3
h 2
/g Re by an angle from the vertical, by replacing g in that
for 30 Re 1800 equation by g cos .
k 1.08 Re1.22 5.2
1/4
For turbulent flow, Labuntsov recommends, hinclined hvert cos for laminar flow
2 1/ 3
h /g Re 1/ 4
for Re 1800 gk 3 v
k 8750 58 Pr 0.5 Re 0.75 253 h 0.943 0 Re 30
Tsat Tw L
(10-22)
Problem: Vertical Tubes
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 Equation 10 22 for vertical plates can also be
maintained at 500C by the flow of cold water through the tube. What is the rate used to calculate the average heat transfer
of heat transfer to the coolant and what is the rate at which steam is condensed coefficient for laminar film condensation on the
at the surface? outer surfaces of vertical tubes provided that the
tube diameter is large relative to the thickness
of the liquid film.
13 14

4 Horizontal Tubes and Spheres Condensation

The average heat transfer coefficient for film condensation Problem:
on the outer surfaces of a horizontal tube is One hundred tube of 12.5 mm diameter arrange in square array and exposed to
1/ 4
gk 3 For a sphere, replace the atmospheric steam. Calculate the mass of steam condensed per unit length of
h 0.725 v
W/m 2 .K tubes for a tube wall temperature of 980C.
Tsat Tw D constant 0.725 by 0.815.

The average heat transfer coefficient, h is determined as

A comparison of the heat transfer coefficient relations for a vertical tube of 1/ 4
height L and a horizontal tube of diameter D yields gk 3 v
h 0.725
Tsat Tw nd
The rate of heat transfer per unit length
For a tube whose length is 2.77 times its diameter, the average heat transfer coefficient for
q A
h (Tsat Tw )
laminar film condensation will be the same whether the tube is positioned horizontally or vertically. L L
For L > 2.77D, the heat transfer coefficient is higher in the horizontal position. Total condensation rate per unit length of tubes can then be obtained
Considering that the length of a tube in any practical application is several times its diameter, it is
common practice to place the tubes in a condenser horizontally to maximize the condensation m q L
heat transfer coefficient on the outer surfaces of the tubes.
L

15 16
FILM CONDENSATION INSIDE
HORIZONTAL TUBES
Most condensation processes encountered in
refrigeration and air-conditioning applications
involve condensation on the inner surfaces of
horizontal or vertical tubes.
Heat transfer analysis of condensation inside
tubes is complicated by the fact that it is strongly
influenced by the vapor velocity and the rate of
liquid accumulation on the walls of the tubes.
For low vapor velocities:
The Reynolds number of the vapor is to be evaluated
at the tube inlet conditions using the internal tube
diameter as the characteristic length.
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.
Dropwise Condensation
Dropwise condensation, characterized by
countless droplets of varying diameters on the
condensing surface instead of a continuous
liquid film and extremely large heat transfer
coefficients can be achieved with this
mechanism.
The small droplets that form at the nucleation
sites on the surface grow as a result of
continued condensation, coalesce into large
droplets, and slide down when they reach a
certain size, clearing the surface and exposing it
to vapor. There is no liquid film in this case to
resist heat transfer.
As a result, with dropwise condensation, heat
transfer coefficients can be achieved that are
more than 10 times larger than those associated
with film condensation.
The challenge in dropwise condensation is not Dropwise condensation of
to achieve it, but rather, to sustain it for steam on copper surfaces:
prolonged periods of time.
17 18
Boiling heat flux from a solid surface to the fluid
excess temperature
Classification of boiling
Boiling is called pool 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.
Boiling is called flow 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.
19 20
 Subcooled Boiling
When the
temperature of the
main body of the
liquid is below the
saturation
temperature.
Saturated Boiling
When the
temperature of the
liquid is equal to the
saturation
temperature.
POOL BOILING
In pool boiling, the fluid is not forced to flow
by a mover such as a pump.
Any motion of the fluid is due to natural
convection currents and the motion of the
bubbles under the influence of buoyancy.
Boiling Regimes and
the Boiling Curve
Boiling takes different forms, depending on
the Texcess = Ts Tsat

21 22

Natural Convection Boiling

(to Point A on the Boiling Curve)
Bubbles do not form on the heating surface until the liquid is heated a few
degrees above the saturation temperature (about 2 to 6 C for water)
The liquid is slightly superheated in this case (metastable state).
The fluid motion in this mode of boiling is governed by natural convection
currents.

Heat transfer from the

heating surface to the fluid
is by natural convection.
For the conditions of Fig.
10 6, natural convection
boiling ends at an excess
temperature of about 5 C.

23 24
Nucleate Boiling (between In region A B the stirring and agitation caused by the entrainment of the liquid to
the heater surface is primarily responsible for the increased heat transfer
Points A and C) coefficient.
The bubbles form at an In region A B the large heat fluxes obtainable in this region are caused by the
increasing rate at an increasing combined effect of liquid entrainment and evaporation.
number of nucleation sites as For the entire nucleate boiling range, the heat transfer coefficient ranges from
we move along the boiling curve about 2000 to 30,000 W/m2·K.
toward point C.
Region A B isolated After point B the heat
bubbles. flux increases at a
lower rate with
Region B C
increasing Texcess, and
numerous continuous reaches a maximum at
columns of vapor in the point C.
liquid. The heat flux at this
point is called the
critical (or maximum)
Point A is referred to as heat flux, and is of
the onset of nucleate prime engineering
boiling (ONB). importance.
25 26

Transition Boiling (between Film Boiling (beyond Point D

Points C and D) Beyond point D the heater
When Texcess is increased past point surface is completely
C, the heat flux decreases. covered by a continuous
stable vapor film.
This is because a large fraction of the Point D, where the heat flux
heater surface is covered by a vapor reaches a minimum is
film, which acts as an insulation. called the Leidenfrost
In the transition boiling point.
regime, both nucleate and The presence of a vapor
film boiling partially occur. film between the heater
Operation in the transition surface and the liquid is
boiling regime, which is also responsible for the low heat
called the unstable film transfer rates in the film
boiling regime, is avoided in boiling region.
practice. The heat transfer rate
For water, transition boiling increases with increasing
occurs over the excess excess temperature due to
temperature range from radiation to the liquid.
about 30 C to about 120 C.
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29
Any attempt to increase the heat
flux beyond qmax will cause the
operation point on the boiling
curve to jump suddenly from
point C to point E.
However, surface temperature
that corresponds to point E is
beyond the melting point of most
heater materials, and burnout
occurs.
Therefore, point C on the boiling
curve is also called the burnout
point, and the heat flux at this
point the burnout heat flux.
Most boiling heat transfer
equipment in practice operate
slightly below qmax to avoid any
disastrous burnout.
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Burnout Phenomenon
A typical boiling process does
not follow the boiling curve
beyond point C.
When the power applied to the
heated surface exceeded the
value at point C even slightly,
the surface temperature
increased suddenly to point E.
When the power is reduced
gradually starting from point E
the cooling curve follows Fig.
10 8 with a sudden drop in
excess temperature when point
D is reached.
30
Heat Transfer Correlations in Pool Boiling
Boiling regimes differ considerably in their character.
Different heat transfer relations need to be used for different boiling regimes.
In the natural convection boiling regime heat transfer rates can be accurately
determined using natural convection relations.
Nucleate Boiling
No general theoretical relations for heat
transfer in the nucleate boiling regime is
available.
Experimental based correlations are
used.
The rate of heat transfer strongly
depends on the nature of nucleation
and the type and the condition of the
heated surface.
32
For nucleate boiling a widely used correlation
proposed in 1952 by Rohsenow:

33 34

Peak Heat Flux Minimum Heat Flux

The maximum (or critical) heat flux (CHF) in nucleate pool boiling:
Minimum heat flux, which occurs at
the Leidenfrost point, is of practical
interest since it represents the lower
Ccr is a constant whose value depends on the heater geometry, but generally is limit for the heat flux in the film
about 0.15. boiling regime.
The CHF is independent of the fluid heating surface combination, as well as Zuber derived the following
the viscosity, thermal conductivity, and the specific heat of the liquid. expression for the minimum heat flux
The CHF increases with pressure up to about one-third of the critical pressure, for a large horizontal plate
and then starts to decrease and becomes zero at the critical pressure.
The CHF is proportional to hfg, and large maximum heat fluxes can be obtained
using fluids with a large enthalpy of vaporization, such as water.

This relation above can be in error by

50% or more.

Transition
boiling
regime
35 36
Film Boiling
The heat flux for film boiling on a horizontal cylinder or
sphere of diameter D is given by
At high surface temperatures
(typically above 300 C), heat transfer
across the vapor film by radiation
becomes significant and needs to be
considered.
37
Surfaces that provide enhanced heat transfer
in nucleate boiling permanently are being
manufactured and are available in the
market.
Heat transfer can be enhanced by a factor of
up to 10 during nucleate boiling, and the
critical heat flux by a factor of 3.
The use of finned surfaces is also known to
enhance nucleate boiling heat transfer and
the maximum heat flux.
Boiling heat transfer can also be enhanced by
other techniques such as mechanical
agitation and surface vibration.
These techniques are not practical, however,
because of the complications involved.
39
Enhancement of Heat Transfer in Pool Boiling
The rate of heat transfer in the
nucleate boiling regime strongly
depends on the number of active
nucleation sites on the surface, and
the rate of bubble formation at
each site.
Therefore, modification that
enhances nucleation on the
heating surface will also enhance
heat transfer in nucleate boiling.
Irregularities on the heating
surface, including roughness and
dirt, serve as additional nucleation
sites during boiling.
38
FLOW BOILING
In flow boiling, the fluid is forced to move
by an external source such as a pump as it
undergoes a phase-change process.
It exhibits the combined effects of
convection and pool boiling.
External flow boiling over a plate or
cylinder is similar to pool boiling, but the
added motion increases both the nucleate
boiling heat flux and the maximum heat
flux considerably.
The higher the velocity, the higher the
nucleate boiling heat flux and the critical
heat flux.
Internal flow boiling, commonly referred to
as two-phase flow, is much more
complicated in nature because there is no
free surface for the vapor to escape, and
thus both the liquid and the vapor are
forced to flow together.
40
 Correlation of flow boiling for water:
The two-phase flow in a tube
exhibits different flow boiling For forced convection local boiling inside vertical tube,
regimes, depending on the
relative amounts of the liquid 3 P
h 2.54 Tx exp
and the vapor phases. 1.551
Note that the tube contains a Where, P is the pressure in mega Pascals
liquid before the bubbly flow
regime and a vapor after the Problem
mist-flow regime.
Heat transfer in those two
cases can be determined
using the appropriate
relations for single-phase
convection heat transfer.

41 42