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Condensation Heat Transfer

The document discusses condensation heat transfer, including film condensation on vertical plates. It provides equations to model the hydrodynamics and thermal considerations of laminar film condensation on a vertical plate, determining the liquid film thickness and heat transfer coefficient based on properties of the condensate and vapor. The heat transfer rate during condensation can be calculated from these models.
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0% found this document useful (0 votes)
265 views37 pages

Condensation Heat Transfer

The document discusses condensation heat transfer, including film condensation on vertical plates. It provides equations to model the hydrodynamics and thermal considerations of laminar film condensation on a vertical plate, determining the liquid film thickness and heat transfer coefficient based on properties of the condensate and vapor. The heat transfer rate during condensation can be calculated from these models.
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
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ME-330

Heat and Mass Transfer


Text: Heat and Mass Transfer – A Practical
Approach
by
Yunus A. Çengel

Chapter 10: Boiling and Condensation


Lecture by: Asst. Prof. NAEEM (SMME - NUST)

Lecture by Asst. Prof. NAEEM 1


Chapter – 10 (Part-II)
(Condensation Heat Transfer)

Lecture by Asst. Prof. NAEEM 2


Condensation: Introduction
• Condensation is reverse of the boiling process
• Condensation sets in when a saturated vapor comes in
contact with a surface whose temperature (Ts) is lower
than the saturation temperature (Tsat) corresponding to
the vapor pressure.
• As vapor condenses, latent heat (hfg) is liberated and
heat flow towards the surface (since Ts < Tsat).
• Liquid condensate may get somewhat sub cooled at the
cold surface.
• It may eventually cause more vapor to condense:
• either on the exposed surface
• or on already formed condensate.
Lecture by Asst. Prof. NAEEM 3
Condensation: Physical Mechanism
Depending upon condition of cool surface, condensation may occur
in two possible ways:
Film condensation Dropwise condensation
• The condensate wets the • The condensed vapor forms
surface and forms a liquid droplets on the surface.
film. • The droplets slide down when
• The surface is blanketed by a they reach a certain size.
liquid film which serves as a • No liquid film to resist heat
resistance to heat transfer. transfer.
• As a result, heat transfer rates
that are more than 10 times
larger than with film
condensation can be achieved.

Lecture by Asst. Prof. NAEEM 4


Film Condensation
• Heat transfer depends upon whether the condensate flow is
laminar or turbulent.
• Criterion, as usual, is the Reynolds number, defined as:
𝐷ℎ𝜌𝑙𝑉𝑙 4𝐴𝑐𝜌𝑙𝑉𝑙 4𝜌𝑙𝑉𝑙𝛿 4𝐴𝑐𝜌𝑙𝑉𝑙 4𝑚ሶ
Re = = = = = (10-8)
𝜇𝑙 𝑝𝜇𝑙 𝜇𝑙 𝑝𝜇𝑙 𝑝𝜇𝑙

Dh = (4Ac /p) = 4 hydraulic diameter of the condensate flow, [m]


p = wetted perimeter of the condensate, [m]
Ac = p = (wetted perimeter  film thickness), [m2]
(Ac is cross-sectional area of the condensate flow at the lowest part of the flow)
𝝆𝒍 = density of the liquid, [kg/m3]
l viscosity of the liquid, [kg/m·s]
Vl = average velocity of the condensate at the lowest part of the flow, [m/s]
𝒎ሶ = 𝜌𝑙 Vl Ac = mass flow rate of the condensate at the lowest part, [kg/s]
Lecture by Asst. Prof. NAEEM 5
Film Condensation
Modified Latent Heat of Vaporization:
• Note that the actual process the condensate is further cooled to some
temperature between Tsat and Ts as vapor loses heat to surface.
• Rohsenow proposed that the actual heat transfer which is larger, can
be account for by replacing hfg by hfg*, such that:

ℎ𝑓𝑔 = hfg + 0.68 cpl (Tsat – Ts) (10-9a)

If superheated vapor at temperature Tv enters the condenser, then


Eqn (10-9a) is further modified as:

ℎ𝑓𝑔 = hfg + 0.68 cpl (Tsat – Ts) + cpv (Tv – Tsat) (10-9b)

With these considerations, the rate of heat transfer can be expressed as:
𝑄ሶ conden= hAs(Tsat – Ts) = 𝑚ℎ ∗
ሶ 𝑓𝑔 (10-10)
As is surface area on which condensation occurs
Lecture by Asst. Prof. NAEEM 6
Film Condensation
Modified Latent Heat of Vaporization:
Consider:
𝐷ℎ𝜌𝑙𝑉𝑙 4𝐴𝑐𝜌𝑙𝑉𝑙 4𝜌𝑙𝑉𝑙𝛿 4𝐴𝑐𝜌𝑙𝑉𝑙 4𝑚ሶ (10-8)
Re = = = = =
𝜇𝑙 𝑝𝜇𝑙 𝜇𝑙 𝑝𝜇𝑙 𝑝𝜇𝑙

and 𝑄ሶ conden= hAs(Tsat – Ts) = 𝑚ℎ ∗


ሶ 𝑓𝑔 (10-10)

Solving for 𝑚ሶ from (10-10) and substituting into (10-8) gives a


simple relation for the Reynolds number if 𝑄ሶ conden is known:
4𝑄ሶ conden 4Ash(Tsat – Ts) (10-11)
Re = ∗ = ∗
𝑝𝜇𝑙 ℎ𝑓𝑔 𝑝𝜇𝑙 ℎ𝑓𝑔
In these relations:
• liquid properties should be evaluated at the film temperature Tf = (Tsat + Ts)/2.
• and hfg at Tsat since it is not affected by the subcooling of the liquid.
Lecture by Asst. Prof. NAEEM 7
Vertical Plate: Flow Regimes
The dimensionless parameter
controlling the transition between
different regimes is the Reynolds
number is defined as:
𝐷ℎ𝜌𝑙𝑉𝑙 4𝐴𝑐𝜌𝑙𝑉𝑙 4𝜌𝑙𝑉𝑙𝛿 4𝐴𝑐𝜌𝑙𝑉𝑙 4𝑚ሶ
Re = = = = =
𝜇𝑙 𝑝𝜇𝑙 𝜇𝑙 𝑝𝜇𝑙 𝑝𝜇𝑙

Three prime flow regimes:


– Re < 30 ─ Laminar (smooth),
– 30 < Re < 1800 ─ Wavy-laminar,
– Re > 1800 ─ Turbulent. Fig. 10-23

The Reynolds number increases in the flow


direction.
Lecture by Asst. Prof. NAEEM 8
Film Condensation on a Vertical Plate
Consider Fig. 10-24:
• Liquid film starts forming at the top of the
plate and flows downward under the
influence of gravity.
• Film thickness ( ) increases in the flow
direction x (positive downwards)
• Heat in the amount hfg is released during
condensation and is transferred through
the film to the plate surface. Fig. 10-24
• Surface temperature (Ts ) must be below the saturation
temperature (Tsat) for condensation to take place.
• The temperature of the condensate is Tsat at the interface
and decreases gradually to Ts at the wall.
Lecture by Asst. Prof. NAEEM 9
Film Condensation on a Vertical Plate
Condensate Velocity and Temperature

• Velocity and temperature profiles are


shown on the figure.
• Condensate velocity:
• zero at plate surface (no slip) and
• maximum at liquid-vapor interface
• Temperature of condensate:
• Tsat at interface
Fig. 10-24
• Decreases gradually to Ts at the plate

Lecture by Asst. Prof. NAEEM 10


Heat Transfer Correlations for
Film Condensation on a Vertical Plate
Assumptions:
1. Both the plate and the vapor are maintained at
constant temperatures of Ts and Tsat.
2. Temperature across the liquid film varies
linearly.
3. Heat transfer across the liquid film is by pure
conduction.
4. The velocity of the vapor is low (or zero) so
that it exerts no drag on the condensate i.e. (no
viscous shear on the liquid–vapor interface).
5. Flow of the condensate is laminar (Re < 30)
6. Properties of the liquid are constant
7. The acceleration of the condensate layer is
Fig. 10-24
negligible.
Lecture by Asst. Prof. NAEEM 11
Vertical Plate: Hydrodynamics
Consider the volume element shown in Fig. 10-24
Newton’s Second Law of Motion:
Weight = (Viscous shear force + Buoyancy force)
or
b = element width
Canceling the plate width b and solving for
du/dy:

Integrating from: y = 0, where (u =0)


to y = y, where u = u(y)

(10-12) Fig. 10-24

Lecture by Asst. Prof. NAEEM 12


Vertical Plate: Hydrodynamics
We had: (10-12)

The mass flow rate of the condensate at a


location x is determined from (continuity):
𝛿(𝑥)
𝑚(x)
ሶ =‫= 𝐴𝑑 𝑦 𝑢𝑙𝜌 ׬‬ 𝑏 ‫=𝑦׬‬0 𝜌𝑙𝑢 𝑦 𝑏𝑑𝑦
(10-13)

Substituting u(y) from Eq. 10-12 in 10-13,


we get:
𝑔𝑏𝜌𝑙 (𝜌𝑙 𝜌𝑣)𝛿3
𝑚(x)
ሶ = − (10-14)
3𝜇𝑙
whose derivative with respect to x is:

(10-15) Fig. 10-24

Lecture by Asst. Prof. NAEEM 13


Vertical Plat: Thermal Considerations
We had: (10-15)

Now the rate of heat transfer from the vapor to


the plate through the liquid film (conduction):

Rearranging: (10-16)

Equating 10-15 and 10-16 and separating the


variables give:

(10-17)
Fig. 10-24

Lecture by Asst. Prof. NAEEM 14


Vertical Plat: Thermal Considerations
Consider the (10-17)
equation:
Integrating from x = 0 where  = 0 to x = x where
 =  (x), the liquid film thickness at any location
x is determined to be:

(10-18)

Since the heat transfer across the liquid film is


assumed to be by pure conduction, the heat transfer
coefficient can be expressed through Newton’s law
of cooling and Fourier law.
Thus the heat transfer rate from the vapor to the
plate at a location x can be expressed as:
Fig. 10-24
(10-19)

Lecture by Asst. Prof. NAEEM 15


Vertical Plat: Thermal Considerations
Consider the equations: and (10-18)

Substituting  (x) from Eq. 10-18,


the local heat transfer coefficient (10-20)
is determined to be:
The average heat transfer coefficient over the entire plate is
determined from its definition by substituting the hx relation and
performing the integration. It gives:

(10-21)

Thus the Nusselt No


becomes:

Lecture by Asst. Prof. NAEEM 16


Vertical Plat: Thermal Considerations
Discussion on Equation 10-21:

(10-21)

Equation 10-21, provides good insight on the functional


dependence of the condensation heat transfer coefficient.
However, It underpredicts the heat transfer!
Limitations:
• It does not take into account the effects of:
• the nonlinear temperature profile in the liquid film and
• the cooling of the liquid below the saturation temperature
• Both of these effects can be accounted for by replacing hfg by
modified latent heat of vaporization (h*fg) given by Eq. 10-9.

Lecture by Asst. Prof. NAEEM 17


Vertical Plat: Thermal Considerations
Laminar Film Condensation over a Vertical Flat Plate:
In Eqn 10-21, when hfg is replaced by by h*fg, the average heat transfer
coefficient for laminar film condensation over a vertical flat plate of
height L is determined to be:

For 0 < Re < 30 (10-22)

Accordingly the corrected Nusselt No:

Note that:
1. The liquid properties are evaluated at the film temperature Tf = (Tsat + Ts)/2.
2. The vapor density and latent heat of vaporization hfg are evaluated at Tsat.

Lecture by Asst. Prof. NAEEM 18


Vertical Plat: Thermal Considerations
Note that at a given temperature, v << l and thus (l − v ≈ l)
except near the critical point of the substance.
Using this approximation and by noting that x=L =kl/hx=L and
hvert = 4/3 hx=L (Eqs. 10-19 and 10-21) give:

(10-23)

Thus the heat transfer coefficient (hvert) in terms of Reynolds No


can be expressed as:
(10-24)

Observation:
The results obtained from the theoretical relations above are in
excellent agreement with the experimental results.
Lecture by Asst. Prof. NAEEM 19
Wavy Laminar Flow on Vertical Plates
Wavy Laminar Flow:
• At Reynolds > 30, waves form at the liquid-
vapor interface although the flow in liquid
film remains laminar.
• The waves at the liquid-vapor interface tend
to increase heat transfer.
• But the analysis becomes complicated and
analytical solutions are difficult to obtain.
• Thus we have to rely on experimental studies.
• The increase in heat transfer due to the wave effect is about 20%,
but it can exceed 50%.
• The exact amount of enhancement depends on the Reynolds
number.

Lecture by Asst. Prof. NAEEM 20


Wavy Laminar Flow on Vertical Plates
Baised on the experimental studies, the following relation for the
average heat transfer coefficient in wavy laminar condensate flow
for v << l and 30 < Re < 1800, is obtained:

(10-25)

A simpler alternative to the relation above as proposed by


Kutateladze is:
hvert, wavy = 0.8 Re0.11 hvert (smooth) (10-26)

A relation for the Reynolds number in the wavy laminar region


can be determined by substituting the h relation of Eq. 10-25
into the Re relation and simplifying. It yields:

(10-27)

Lecture by Asst. Prof. NAEEM 21


Turbulent Flow on Vertical Plates
The condensate flow becomes turbulent
when Reynolds number is about 1800.
Several empirical relations of varying
degrees of complexity are proposed for the
heat transfer coefficient for turbulent flow.
For the turbulent flow of condensate
on vertical plates, Labuntsov
proposed the following relation:

(10-28)

The Reynolds No relation in this case is:

(10-29)

Lecture by Asst. Prof. NAEEM 22


Nondimensionalized Heat Transfer
Coefficients

Fig. 10-26: Nondimensionalized heat transfer coefficients for the


wave-free laminar, wavy laminar, and turbulent flow of
condensate on vertical plates.
Lecture by Asst. Prof. NAEEM 23
Heat Transfer Correlations for
Film Condensation
Inclined Plates
Recall equation 10-12 that
was developed for vertical
plates:
(10-12)

• The same expression can also be used by


Fig. 10-27
adjusting ‘g’ for laminar film condensation on
the upper surfaces of plates that are inclined by
an angle with vertical direction.
• This equation gives satisfactory results if used for inclined
plates by replacing gravity (g) by (g cos ) for   60o.

Lecture by Asst. Prof. NAEEM 24


Heat Transfer Correlations for
Film Condensation
Inclined Plates

• The condensation heat transfer


coefficients on vertical and inclined
plates are related to each other by:
hinclined = hvert(cos )1/4 (10-30)

Fig. 10-27
• Equation 10–30 is developed for
laminar flow of condensate, but it can
also be used for wavy laminar flows as
an approximation.

Lecture by Asst. Prof. NAEEM 25


Heat Transfer Correlations for
Film Condensation
Vertical Tubes
Consider equation 10-22 that was developed for vertical
plates:

(10-22)

The same equation can also be used to calculate the average heat
transfer coefficient for laminar film condensation on the outer
surfaces of vertical tubes.
Condition for validity:
The tube diameter should be larger relative to the thickness of the
liquid film.

Lecture by Asst. Prof. NAEEM 26


Heat Transfer Correlations for
Film Condensation
Horizontal Tubes and Spheres
Nusselt’s analysis of film condensation on vertical plates can also be
extended to horizontal tubes and spheres.
The average heat transfer coefficient for film condensation on the
outer surfaces of a horizontal tube is determined to be:
(10-31)

Equation 10-31 can easily be modified for a sphere by replacing the


constant 0.729 by 0.815.
A comparison of the heat transfer coefficient relations for a vertical
tube of height L and a horizontal tube of diameter D yields:
(10-32)

Lecture by Asst. Prof. NAEEM 27


Heat Transfer Correlations for
Film Condensation
Horizontal Tubes and Spheres
• It is observer that for a tube whose length is 2.77 times its
diameter, the average heat transfer coefficient for laminar film
condensation will be the same whether the tube is positioned
horizontally or vertically.
• For L > 2.77D, the heat transfer coefficient will be higher in the
horizontal position.
Engineering Application:
• Since normally 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.
• It maximizes the condensation heat transfer coefficient on the
outer surfaces of the tubes.
Lecture by Asst. Prof. NAEEM 28
Heat Transfer Correlations for
Film Condensation
Horizontal Tubes Banks
• Horizontal tubes banks are commonly used in condenser
design.
• The average thickness of the liquid film at the lower tubes
is much larger as a result of condensate falling on top of
them from the tubes directly above.
• Hence the average heat transfer coefficient at the lower
tubes in such arrangements is smaller. Fig. 10-28

• For smooth drain of the condensate from top to bottom, the average
film condensation heat transfer coefficient for all tubes in a vertical tier
are expressed as:
(10-33)

This relation does not account for increase in heat transfer due to the ripple
formation and turbulence caused during drainage, and thus generally yields
conservative results.
Lecture by Asst. Prof. NAEEM 29
Heat Transfer Correlations for
Film Condensation
Effect of Vapor Velocity
• So far we neglected the vapor drag exerted on the liquid film for small
vapor velocity.
• However, for high vapor velocity, the vapor will “pull” the liquid at the
interface along since the vapor velocity at the interface must drop to the
value of the liquid velocity.
• If the vapor flows downward along with liquid, this additional force will:
• increase the average velocity of the liquid
• decrease the film thickness
• This, in turn, will decrease the thermal resistance of the liquid film and
thus increase heat transfer.
On the contrary, upward vapor flow:
• exerts a force on the liquid in the opposite direction to flow
• thickens the liquid film, and
• Thus decreases heat transfer
Lecture by Asst. Prof. NAEEM 30
Heat Transfer Correlations for
Film Condensation
Presence of Non-condensable Gases in Condensers Fig. 10-29
Experimental studies show that the presence of non-
condensable gases in the vapor cause significant drops
in heat transfer coefficient during condensation.
Reason:
When the vapor mixed with a non-condensable gas
condenses, only the non-condensable gas remains in
the vicinity of the surface (see Fig).
This gas layer acts as a barrier between the vapor and
the surface, and makes it difficult for the vapor to
reach the surface.
The vapor now must diffuse through the non-condensable gas first
before reaching the surface, this reduces the effectiveness of the
condensation process.
Lecture by Asst. Prof. NAEEM 31
Heat Transfer Correlations for
Film Condensation
Presence of Non-condensable Gases in Condensers
Amount of Loss:
It is shown experimentally that the presence of less than 1% (by mass)
of air in steam can reduce the condensation heat transfer coefficient by
more than half.
Remedy:
• To ensure proper operation the non-condensable gases are
periodically vented out.
• Note that heat transfer in the presence of a non-condensable gas
strongly depends on the nature of the vapor flow and the flow
velocity.
• Thus, a high flow velocity is more likely to remove the stagnant non-
condensable gas from the vicinity of the surface, and thus improve
heat transfer.
Lecture by Asst. Prof. NAEEM 32
Film Condensation
Inside Horizontal Tubes Fig. 10-34

Heat transfer analysis of condensation inside


tubes is complicated by the fact that:
• Condensate flow is restricted within the tube
diameter
• It is strongly influenced by the vapor velocity and the rate of liquid
accumulation on the walls of the tubes
For low vapor velocities, Chato recommends the following expression for
condensation:

and
Note that Reynolds number of the vapor is to be evaluated at the tube inlet
conditions using the internal tube diameter as the characteristic length.
Lecture by Asst. Prof. NAEEM 33
Dropwise Condensation
In Dropwise condensation the vapor condenses Fig. 10-35

into small liquid droplets of various sizes which


fall down the surface in random fashion.
Process:
• Small droplets that form at the nucleation sites on
the surface grow as a result of continued
condensation
• Then they break away from the surface and coalesce into large droplets
• Slide down under the influence of gravity when they reach a certain
size
• Thus clearing the surface and exposing it to vapor
• As such, a large portion of the area of solid surface is directly exposed
to vapor without an insulating film of condensate liquid.
• Consequently higher heat transfer rate (to the order of 750 kw/m2) are
achieved.
Lecture by Asst. Prof. NAEEM 34
Dropwise Condensation
• Dropwise condensation has been observed to Fig. 10-35
occur either on highly polished surfaces, or on
surfaces contaminated with impurities like fatty
acids and organic compounds.
• This type of condensation gives coefficient of
heat transfer generally 5 to 10 times larger than
that of film condensation.
• Although dropwise condensation would be preferred over film wise
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 approved.
• For this reason the condensing equipment in use is designed on the
basis of film wise condensation.
Lecture by Asst. Prof. NAEEM 35
End of Lecture on
Condensation

Lecture by Asst. Prof. NAEEM 36


Attempt Text Book Examples
10-4, 10-5, 10-6 and 10-7
and
Also Some Selected End Chapter
Problems
From your Text Book!

Lecture by Asst. Prof. NAEEM 37

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