CONDENSATION

Class N° 19

Facultad de minas
 2

OBJECTIVES
WHAT WE KNOW

 Condensation of a vapor to the liquid state results in heat transfer to the solid
surface.

 Since there is fluid motion involved, boiling and condensation are classified as
forms of the convection mode of heat transfer.

WHAT WE EXPECT

 To develop an appreciation for the physical conditions associated with

condensation.

 To provide a basis for performing related heat transfer calculations.

 3

CONDENSATION (Physical Mechanisms)

[ Condensation occurs when the temperature of a

vapor is reduced below its saturation temperature. ]
Modes of Condensation
 Film condensation: the liquid film covers the entire condensing surface. Is
characteristic of clean, uncontaminated surfaces (Fig. 1a).

 Dropwise condensation: The drops form in cracks, pits, and cavities on the surface
and may grow and coalesce through continued condensation (Fig. 1b).

 Homogeneous condensation: Vapor condenses out as droplets suspended in a gas

phase to form a fog (Fig. 1c).
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CONDENSATION (Physical Mechanisms)

 Direct condensation: Occurs when vapor is brought into contact with a cold liquid
(Fig. 1d).

Figure 1. Modes of condensation. (a) Film. (b) Dropwise condensation on a

surface. (c) Homogeneous condensation. (d) Direct contact condensation.
 5

CONDENSATION (Physical Mechanisms)

Film and dropwise condensation of steam on a vertical copper surface are shown in
Figure 2.

Figure 2. Condensation on a vertical surface. (a) Dropwise. (b) Film.

Regardless of whether it is on the form of a film or droplets, the condensate provides a

resistance to heat transfer between the vapor and the surface.
 6

CONDENSATION (Physical Mechanisms)

Video 4. Dropwise Vs. film condensation.

 7

LAMINAR FILM CONDENSATION (On a Vertical plate)

Assumptions:
1. Laminar flow and constant properties.

2. The gas is a pure vapor, and at a uniform temperature equal to .

3. The shear stress at the liquid-vapor interface is assumed to be negligible, in

which case .

4. Momentum and energy transfer by advection in the condensate film are

assumed to be negligible.

Film conditions resulting from the assumptions are shown in Figure 3b.

From the fourth approximation, momentum advection terms may be neglected,

and the -momentum equation may be expressed as
 8

LAMINAR FILM CONDENSATION (On a Vertical plate)

Figure 3. Boundary layer

effects related to film
condensation on a vertical
surface. 8a) Without
approximation. (b) With
assumptions associated with
Nusselt’s analysis, for a
vertical plate of width b.
 9

LAMINAR FILM CONDENSATION (On a Vertical plate)

𝜕2 𝑢 𝑔
=− ( 𝜌𝑙 − 𝜌
(1) 𝑣 )
𝜕 𝑦 2
𝜇𝑙
Integrating twice and applying boundary conditions of the form and , the velocity
profile in the film becomes

𝑔 ( 𝜌 𝑙 − 𝜌 𝑣 ) 𝛿2
[ ( ) ]
2
𝑦 1 (2) 𝑦
𝑢( 𝑦 )= −
𝜇𝑙 𝛿 2 𝛿

From this result the condensate mass flow rate per unit width may be obtained in
terms of an integral involving the velocity profile:
𝛿 (𝑥)
˙ (𝑥 )
𝑚
𝑏
= ∫ 𝜌 𝑙 𝑢 ( 𝑦 ) 𝑑𝑦 ≡ Γ
(3) ( 𝑥 )
0

Substituting from Equation 3, it follows that

 10

LAMINAR FILM CONDENSATION (On a Vertical plate)

3
𝑔 𝜌𝑙 ( 𝜌𝑙 − 𝜌 𝑣 ) 𝛿
Γ ( 𝑥)= (4)
3 𝜇𝑙

At a portion of the liquid-vapor interface of unit width and length , the rate of heat
transfer into the film, , must equal the rate of energy release due to condensation at
the interface. Hence

𝑑𝑞 =h 𝑓𝑔 𝑑 𝑚
(5)˙

Since advection is neglected, it also follows that the rate of heat transfer across the
interface must equal the rate of heat transfer to the surface. Hence

𝑑𝑞 =𝑞}
s
left (𝑏 ∙ 𝑑𝑥 right
(6)
¿

Since the liquid temperature distribution is linear, Fourier’s law may be used to
express the surface heat flux as
 11

LAMINAR FILM CONDENSATION (On a Vertical plate)

} = {{𝑘} rsub {𝑙} left ({𝑇} rsub {sat} − {𝑇} rsub {𝑠} right )} over(7){δ ¿
𝑞 s
Combining Equations 3 and 4 through 6, we then obtain

𝑑 Γ 𝑘 𝑙 ( 𝑇 sat − 𝑇 𝑠 )
= (8)
𝑑𝑥 δ h 𝑓𝑔
Differentiating Equation 4, we also obtain
2
𝑑 Γ 𝑔 𝜌 𝑙 ( 𝜌 𝑙 − 𝜌 𝑣 ) 𝛿 𝑑 (9)
𝛿
=
𝑑𝑥 𝜇𝑙 𝑑𝑥

Combining Equations 8 and 9, it follows that

 12

LAMINAR FILM CONDENSATION (On a Vertical plate)

Integrating from , where , to any -location of interest on the surface,

[ ]
1 /4
4 𝑘 𝑙 𝜇 𝑙 ( 𝑇 sat − 𝑇 𝑠 ) 𝑥
𝛿( 𝑥 )= (10)
𝑔 𝜌 𝑙 ( 𝜌 𝑙 − 𝜌 𝑣 ) h 𝑓𝑔

This result may then be substituted into Equation 4 to obtain .

In lieu of , it is recommended using a modified latent heat of the form, or in terms of ,

h′𝑓𝑔 =h 𝑓𝑔 ( 1+ 0.68 𝐽𝑎
(11) )
The surface heat flux may be expressed as

𝑞}s = {h} rsub {𝑥} left ({𝑇} rsub {sat} − {𝑇} rsub {𝑠(12)
} right ¿
 13

LAMINAR FILM CONDENSATION (On a Vertical plate)

Substituting form Equation 7, the local convection coefficient is then

𝑘𝑙
h 𝑥 = (13)
𝛿
Or, from Equation 10, with replaced by,

[ ]
1/ 4
𝑔 𝜌 𝑙 ( 𝜌 𝑙 − 𝜌 𝑣 ) 𝑘3
𝑙 h ′
𝑓𝑔
h 𝑥= (14)
4 𝜇 𝑙 ( 𝑇 sat − 𝑇 𝑠 ) 𝑥
Since depends on , it follows that the average convection coefficient for the
entire plate is

[ ]
3 ′ 1/ 4
𝑔 𝜌 𝑙 ( 𝜌 𝑙 − 𝜌𝑣 ) 𝑘 h 𝑙 𝑓𝑔
h 𝐿 =0.943 (15)
𝜇𝑙 ( 𝑇 sat − 𝑇𝑠 ) 𝐿
The average Nusselt number then has the form
 14

LAMINAR FILM CONDENSATION (On a Vertical plate)

[ ]
′ 3 1/ 4
h𝐿 𝐿 𝜌 𝑙 𝑔 ( 𝜌𝑙 − 𝜌 𝑣 ) h 𝐿 𝑓𝑔
𝑁𝑢 𝐿 = = 0.943 (16)
𝑘𝑙 𝜇 𝑙 𝑘 𝑙 ( 𝑇 sat − 𝑇 𝑠 )

In using this equation in conjunction with Equation 11, all liquid properties should be
evaluated at the film temperature . The vapor density and latent heat of vaporization
should be evaluated at .
The total heat transfer to the surface may be obtained by using Equation 15 with the
following form of Newton’s law of cooling:

𝑞 =h 𝐿 𝐴 ( 𝑇 sat − 𝑇
(17) 𝑠 )
The total condensation rate may then be determined from the relation

𝑞 h𝐿 𝐴 ( 𝑇 sat − 𝑇 𝑠 )
𝑚=
˙ ′
= ′ (18)
h 𝑓𝑔 h 𝑓𝑔
 15

TURBULENT FILM CONDENSATION

(On a Vertical plate)
Consider the vertical surface of Figure 4a. The transition criterion maybe expressed in
terms of a Reynolds number defined as

4 Γ
𝑅𝑒 𝛿 ≡ (19)
𝜇𝑙
With the condensate mass flow rate given by , the Reynolds number may be
expressed as

4𝑚 ˙ 4 𝜌𝑙 𝑢𝑚 𝛿
𝑅𝑒 𝛿 ≡ = (20)
𝜇𝑙 𝑏 𝜇𝑙

Where is the average velocity in the film and , the film thickness, is the characteristic
length.

For the wave-free laminar regime , Equations 19 and 4 may be combined to yield
 16

TURBULENT FILM CONDENSATION

(On a Vertical plate)

Figure 4. Film condensation on a vertical plate. (a) Condensate

rate for plate of width b. (b) Flow regimes.
 17

TURBULENT FILM CONDENSATION

(On a Vertical plate)
4 𝑔 𝜌𝑙 ( 𝜌𝑙 − 𝜌 𝑣 ) 𝛿3
𝑅𝑒 𝛿 ≡ 2
(21)
3𝜇 𝑙

An average modified Nusselt number associated with condensation in the wave-free

laminar regime has the form
1/ 3
h𝑙 ( 𝜈 𝑙 / 𝑔 )
2
− 1/ 2
𝑁𝑢 𝐿 ≡ =1.47 𝑅𝑒 𝛿 𝑅𝑒
(22)𝛿 ≤ 30
𝑘𝑙
Where the average heat transfer coefficient is associated with condensation over the
entire plate. When the flow at the bottom of the plate is in the laminar, wavy regime, it
is recommended a correlation of the form
1/ 3
h𝑙 ( 𝜈 𝑙 / 𝑔 )
2
𝑅𝑒 𝛿
𝑁𝑢 𝐿 ≡ = 30 ≤ 𝑅𝑒(23)
𝛿 ≤ 180 0
𝑘𝑙 1.08 𝑅𝑒 1.22
𝛿 − 5.2
 18

TURBULENT FILM CONDENSATION

(On a Vertical plate)
And when the flow at the bottom of the plate is in the turbulent regime, the
recommended correlation is

(24)

Graphical representation of the foregoing correlations is provided in Figure 5. All

properties are evaluated as for laminar film condensation.
The Reynolds number in Equations 22 through 24 is associated with the film thickness
that exists at the bottom of the condensing surface, .
1 /3
h𝑙 ( 𝜈 / 𝑔 )
2
𝑙 (25)
𝑅𝑒 𝛿 = 4 𝑃 = 4 𝑃 𝑁𝑢 𝐿
𝑘𝑙
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TURBULENT FILM CONDENSATION

(On a Vertical plate)

Where the dimensionless parameter is

𝑘𝑙 𝐿 ( 𝑇 sat −𝑇 𝑠 )
𝑃= 1/ (26)
3
𝜇𝑙 h′𝑓𝑔 (𝜈 2
𝑙 / 𝑔)
 20

FILM CONDENSATION
(On a Vertical plate)
Substituting Equation 25 into Equations 22, 23, and 24, we can solve for the average
Nusselt numbers in terms of to yield
1 /3
h𝑙 ( 𝜈 𝑙 / 𝑔 )
2

𝑁𝑢 𝐿 = = 0.943 𝑃 − 1 /4 𝑃 ≤ 15.8
(27)
𝑘𝑙
1 /3
h𝑙 ( 𝜈 / 𝑔 )
2
𝑙 1
𝑁𝑢 𝐿 = = ( 0.68 𝑃+ 0.89 )0.82 15.8 ≤ 𝑃 ≤ 2530
(28)
𝑘𝑙 𝑃

(29)
 21

FILM CONDENSATION (On Radial System)

For laminar film condensation on the outer surface of a sphere or a horizontal tube (Fig.
6a,b), the average Nusselt number has the form

[ ]
1 /4
h𝐷 𝐷 𝜌 𝑙 𝑔 ( 𝜌 𝑙 − 𝜌 𝑣 ) h′𝑓𝑔 𝐷3
𝑁𝑢 𝐷 = =𝐶 (30)
𝑘𝑙 𝜇 𝑙 𝑘 𝑙 ( 𝑇 sat − 𝑇 𝑠 )

Where for the sphere and for the tube.

When a liquid-vapor surface interface is curved (Fig. 6), pressure differences are
established across the interface by effects of surface tension:
𝜎
∆ 𝑝= 𝑝𝑣 − 𝑝 𝑙= (31)
𝑟𝑐
Where is the local radius of curvature of the liquid-vapor interface.
 22

FILM CONDENSATION (On Radial System)

Condensation on a tube with annular fins
is shown in Figure 7. Heat transfer rates
for the finned tube may be related to
those for a corresponding unfinned tube
by an enhancement ratio, .

The degree of enhancement depends

primarily on:
 The fluid.
 The ambient pressure.
 The fin geometry.

Figure 6. Film condensation on (a) a sphere, (b) a single

horizontal tube, (c) a vertical tier of horizontal tubes with a
continuous condensate sheet, and (d) with dripping condensate.
 23

FILM CONDENSATION (On Radial System)

The minimum enhancement occurs when condensate is retained in the entire inter-fin
region, and is

[ ]
1/ 4
𝑞 ft , min 𝑡𝑟2 𝑟1 𝜎 𝑟1
𝜀 ft , min = = +1.02 (32)
𝑞uft 𝑆 𝑟1 𝑟2 ( 𝜌𝑙 − 𝜌𝑣 ) 𝑔 𝑡 3

Where and are evaluated as described below Equation 16 and the surface tension is
evaluated at .

[ To Take Into Account…

Actual enhancements exceed and have been reported

to be in the range for water. ]
 24

FILM CONDENSATION (On Radial System)

For vertically unfinned, aligned tubes the
average coefficient may be expressed as

𝑁𝑛
h 𝐷 , 𝑁 =h 𝐷 (33)
Where is the heat transfer coefficient for
the top tube given by Equation 33.

Figure 7. Condensation on a horizontal finned

tube.

If the length-to-diameter ratio of an unfinned tube exceeds , Equations 30 and 33

may be applied to inclined tubes by replacing with , where the angle is measured
from the horizontal position.
 25

CONDENSATION (In Horizontal Tubes)

Conditions within the tubes depend strongly on:

 The velocity of the vapor flowing through the tube.

 The mass fraction of vapor .
 The fluid properties.

If the vapor velocity is small, condensation occurs in the manner depicted in Figure 8a
for a horizontal tube .
For low vapor velocities such that

𝑅𝑒 𝑣 , 𝑖 =
( 𝜌 𝑣 𝑢𝑚 , 𝑣 𝐷
𝜇𝑣 ) 𝑖
< 35,000
(34)

Where refers to the tube inlet, heat transfer occurs predominantly through the falling
condensate film.
 26

CONDENSATION (In Horizontal Tubes)

It is recommended the use of Equation 10.46 with and

Figure 8. Film condensation in a horizontal tube. (a) Cross section of condensate flow for low vapor
velocities. (b) Longitudinal section of condensate flow for large vapor velocities. (c) Microfins arranged in a
helical pattern.

At high vapor velocities the two-phase flow becomes turbulent and annular (Fig. 8b). A
recommended empirical correlation for a local heat transfer coefficient is of the form
 27

REFERENCES
TEXTS AND TABLES
Bergman, T. et al. Fundamentals of Heat and Mass Transfer. John Wiley & Sons, 2011.

VIDEOS

Video 1: Varanasigroup. Dropwise Vs. filmwise condensation [on line]. Available on:
< http://www.youtube.com/watch?v=9PBOt4kkCfU&feature=related>. Last view: November 2nd, 2012.

FIGURES

Bergman, T. et al. Fundamentals of Heat and Mass Transfer. John Wiley & Sons, 2011.

Cengel, Y. A., & Ghajar, A. J. Transferencia de calor y masa (4th ed.). New York: New York:
Mc Graw Hill 2011.