Department of Mechanical Engineering

ME-409 Heat Transfer, Refrigeration and Air Conditioning Lab

Experiment No. 04
Experiment Name: Study of Heat Transfer through Extended Surfaces

Name of Student: Abdul Rehman

Signature of Student: ____________________________
Registration No.: 04-3-1-43-2020
Date of Experiment: 04/08/2024
Group: A1
Report Marks: _____ out of 10.

Date of Report Submission: 05/17/2024

Lab Engineer’s Name: Abdullah
Signature of Lab Engineer: ______________________
 Table of Contents
3.1 Abstract ...................................................................................................................................... 6
3.2 Introduction ............................................................................................................................... 6
3.3 Experimental Setup .................................................................................................................... 6
3.4 Theory ........................................................................................................................................ 7
3.5.1 Condensation......................................................................................................................... 7
3.5.2 Film Wise Condensation ........................................................................................................ 7
3.5.3 Dropwise Condensation ........................................................................................................ 8
3.5 Procedure................................................................................................................................... 8
3.5.4 General Operating Procedure ............................................................................................... 8
3.5.5 General Start Up Procedure .................................................................................................. 9
3.5.6 Procedure of Experiment ...................................................................................................... 9
3.6 Observation and Calculation .................................................................................................... 10
3.7 Sample Calculations: ................................................................................................................ 13
3.8 Discussion ................................................................................................................................ 14
3.9 Conclusion ................................................................................................................................ 14
 List of Figures

Figure 1 Experimental Setup ..................................................................................................... 6

Figure 2 Heat Flux Vs Temp Diff ............................................................................................ 11
Figure 3 Heat Transfer Coefficient vs Temp Diff ................................................................... 11
Figure 4 Heat Transfer Coefficient vs Temp Diff ................................................................... 12
Figure 5 Heat Transfer Coefficient vs Temp Diff ................................................................... 13
 List of Tables
Table 1 Film Wise Condensation ............................................................................................. 10
Table 2 Drop Wise Condensation ............................................................................................ 12
3.1 Abstract
This experiment aimed to compare the heat flux and heat transfer coefficient of dropwise versus
film wise vapor condensation. The results showed a significant advantage of dropwise
condensation over film wise condensation, with the former having ten times higher heat flux.
The film formed during film wise condensation acted as a barrier, limiting heat transfer, while
dropwise condensation promoted greater heat exchange by increasing surface exposure.
Nonlinearity in the trends was attributed to experimental errors such as heat loss, temperature
fluctuations, and inaccurate measurements caused by inadequate insulation, inconsistent power
supply, and faulty pressure gauges. The study suggests that better insulation, a vacuum to
remove air, precise power sources, and standardized operating conditions could improve
accuracy. Repeating the experiment and using a clear experimental protocol could increase
reliability.

3.2 Introduction
The use of steam both for power production and to convey heat has a long history and its use
in these fields is likely to continue into the foreseeable future. In all applications, the steam
must be condensed as it transfers heat to a cooling medium which could be the cold water in
the condensers of generating station, hot water in heating calorifier, a sugar solution in a sugar
refinery etc. During condensation very high heat fluxes are possible and provided the heat can
be quickly transferred from the condensing surface into the cooling medium, steam using heat
exchangers can be compact and effective. Steam may condense onto a surface in two distinct
modes, known as Film wise & dropwise. For the same temperature difference between the
steam and the surface, dropwise condensation is several times more effective than film wise,
and for this reason the former is desirable although in practical plants, it seldom occurs for
prolonged periods.

3.3 Experimental Setup

Model: EES-TH-3126

Figure 1 Experimental Setup

3.4 Theory
Condensation
Condensation of a 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 coefficients. Condensation occurs when a
saturated vapor such as steam meets a solid whose surface temperature is below the saturation
temperature, to form a liquid such as water. Normally, when a vapor condenses on a surface
such as a vertical or horizontal tube or other surface, a film of condensate is formed on the
surface and flows over the surface by the action of gravity. It is this film of liquid between the
surface and the vapor that forms the main resistance to heat-transfer. This is called film wise
condensation. Another type of condensation, dropwise condensation, can occur, where small
drops are formed on the surface. These drops grow and coalesce, and the liquid flows from the
surface. During this condensation, large areas of tube are devoid of any liquid and are exposed
directly to the vapor. Very high rates of heat-transfer occur on these bare areas. The average
coefficient can be as high as 110 000 W/m2 ·K (20 000 btu/h.ft2·°F), which is five to 10 times
larger than film-type coefficients. Film-condensation coefficients are normally much greater
than those in forced convection and are on the order of magnitude of several thousand W/m2.
K or more.

Film Wise Condensation

Unless specially treated, most materials are wetting and as condensation occurs a film of
condensate spreads over the surface. The thickness of the film depends upon a number of
factors such as (1) the rate of condensation, (2) the viscosity if the condensate and (3)
orientation of condensing surface, whether vertical, horizontal or inclined. As fresh vapor
condenses on top of film, the heat of condensation has to pass by conduction through the film
to the metal surface beneath. As the film thickness; it flows downward and drips from the low
points leaving the film intact and at an equilibrium thickness.
Film-Condensation coefficients for vertical surfaces
Film-type condensation on a vertical wall or tube can be analyzed 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 it flows downward because of condensation. Nusselt
(Hl, Wl) assumed that the heat transfer from the condensing vapor at T sat K, through this
liquid film, and to the wall at Tw K was by conduction. Equating this heat-transfer by
conduction to that from condensation of the vapor, a final expression can be obtained for the
average heat-transfer coefficient over the whole surface.
The recommended expression for vertical surfaces in laminar flow is:
where p, is the density of liquid in kg/m3 and pv that of the vapor, g is 9.8066 m/s2, L is the
vertical height of the surface or tube in m, µ, is the viscosity of liquid in Pa ·s, k1 is the liquid
thermal conductivity in W/m ·K, ΔT = Tsat - Tw in K, and hfg is the latent heat of condensation
in J/kg at Tsat. All physical properties of the liquid except hfg are evaluated at the film
temperature Tf = (Tsat + Tw)/2.

Dropwise Condensation
When the condensate does not wet the surface, it forms the droplets on the surface, it is known
as “dropwise condensation”. When the surface tension is large, the condensate coalesces into
a multitude of droplets of different sizes. With time, each droplet grows as more vapor
condenses on its exposed surface. The formation of each droplet is initiated at a point of surface
imperfection (pit, scratch, etc.) and such sites are called “nucleation sites”. At some time, the
tangential pull of gravity, or sheer force exerted by the vapor stream, dislodges the droplet and
carries it downstream. The moving droplet devours the smaller droplets in its path, thereby
creating a clean trail ready for the generation of new droplets of smaller sizes. This surface
renewal process occurs periodically as the droplets accumulate and grow in size. Since the
condensation rate is the highest in the absence of condensate on the surface, the periodic
cleaning performed by the large drops renews finite size regions of the surface for the restart
of the condensation. This surface renewal process is the main reason why dropwise
condensation is a highly effective heat transfer mechanism. The heat transfer coefficient is
roughly ten times greater than the corresponding condensation in the form of thin film. In the
design of condensers, whose function is to cool a vapor stream and to convert it into liquid,
there is a great advantage to promote the breakup of the condensate into droplets. This can be
achieved by:
➢ Coating the solid surface with an organic substance like wax, oil, oleic acid, etc.
➢ Injecting non-wetting chemicals into the vapor, which get deposited on the surface of the
condenser.
➢ Coating the surface with a polymer of low surface energy like Teflon, silicone, etc. or with a
noble metal like gold, silver, etc.
The mechanism of dropwise condensation is complex because of its intermittent time
dependent character, effect of surface tension (due to drop size and shape) and the uncertainty
associated with the location of nucleation sites and the time when the largest droplet will start
its downstream movement.

3.5 Procedure
General Operating Procedure
Temperature Selection
To read a particular temperature.
For film-wise
 Tl = Surface temperature
T3 = Water in, Tin
T5 = Water out, Tout
For dropwise
T2 = Surface temperature
T4 = Water in, Tin
T6 = Water out, Tout
Cooling Water Flow Selection
Flow meters for film wise and drop wise condensers are connected separately on left and right
side of heater.
Heater Setting
To tum on the heater, simply switch the heater switch to "ON" position. The power supply to
the heater is controlled by regulator.
Cooling Water Control
The cooling water flowrate can be controlled by simply turning the valve clockwise to reduce
flowrate and vice versa.

General Start Up Procedure

➢ Ensure that the main switch is in the off position.
➢ Tum the power regulator knobs fully anti-clockwise to set the power to mm1mum.
➢ Fill the chamber with distilled water until the water level stays between the heater and baffle
plates. Always make sure that the heater is fully immersed in the water during throughout the
experiment.
➢ Adjust the water flowrate to the condenser by controlling the control valve according to the
experimental procedure.
➢ Tum on the main switch, follows by the heater switch. Set the heater power by rotating the
power regulator clockwise to increase the heating power.
➢ Observe the water temperature reading; it should increase when the water started to heat-up.
➢ Let the system to stabilize then take all relevant measurements for experimental purposes. Make
adjustment if required.

Procedure of Experiment
For film wise condensation
 ➢ Circulate the cooling water through the film wise condenser starting with the minimum value
of 0.2 Liter/min.
➢ Adjust the heater to obtain the desired pressure at 1.01 bar.
➢ When the condition is stabilized, record the steam (Tsat) & surface temperature (Tsurf), Tin
(T3) & Tout (T5), and flowrate.
For dropwise condensation
➢ Circulate the cooling water through the film wise condenser starting with the minimum value
of 1 Liter/min.
➢ Adjust the heater to obtain the desired pressure at 1.01 bar.
➢ When the condition is stabilized, record the steam (Tsat) & surface temperature (Tsurf), Tin
(T3) & Tout (T5), and flowrate.

3.6 Observation and Calculation

Table 1 Film Wise Condensation

Film Wise Condensation

Pressure=1.01 bar
Heat
Heat
Flow Flow Rate Tsat- Transfer
Power Tin Tout Tsat Tsurface Flux
Rate m Tsur Coefficient
Φ
h
(LPM) (kg/s) (W) 0C 0C 0C 0C 0C (W/m2) (W/m2.K)
0.8 0.013293333 115 19.5 20.9 100 23.7 76.3 17216.9 225.6477
1 0.016616667 221 19.5 20.7 100 23.4 76.6 18446.7 240.8185
1.1 0.018278333 223.8 19 20 100 23.3 76.7 16909.5 220.4625
1.2 0.01994 306.2 18.7 19.8 100 22.7 77.3 20291.4 262.5015
1.3 0.021601667 113 18.9 20 100 22.5 77.5 21982.3 283.6427
1.4 0.023263333 162 18.9 19.9 100 22.4 77.6 21521.1 277.3343
1.5 0.024925 267 19.2 20.2 100 22 78 23058.4 295.6201
1.6 0.026586667 266.4 19 20 100 21.9 78.1 24595.6 314.9244
 Heat Flux Vs Temp Diff
30000

25000

20000

15000

10000

5000

0
76 76.5 77 77.5 78 78.5

Figure 2 Heat Flux Vs Temp Diff

Heat Transfer Coefficient vs Temp Diff

350

300

250

200

150

100

50

0
76 76.5 77 77.5 78 78.5

Figure 3 Heat Transfer Coefficient vs Temp Diff

 Table 2 Drop Wise Condensation

Drop Wise Condensation

Pressure=1.01 bar
Heat
Flow Rate Tsat- Heat Flux Transfer
Flow Rate Power Tin Tout Tsat Tsurface
m Tsur Φ Coefficient
h
(LPM) (kg/s) (W) 0C 0C 0C 0C 0C (W/m2) (W/m2.K)
0.8 0.011466667 115 16 22.4 100 22.9 77.1 67890.749 880.5545
1 0.014333333 221 16 21.9 100 22.6 77.4 78233.48 1010.7685
1.1 0.015766667 223.8 16.3 22.1 100 22.2 77.8 84598.238 1087.3809
1.2 0.0172 306.2 16 21.7 100 21.9 78.1 90697.797 1161.3034
1.3 0.018633333 113 15.9 21.7 100 21.6 78.4 99979.736 1275.2517
1.4 0.020066667 162 16 21.4 100 21.1 78.9 100244.93 1270.5315
1.5 0.0215 267 16.1 21.8 100 20.9 79.1 113372.25 1433.2775
1.6 0.022933333 266.4 15.9 21.3 100 20.7 79.3 114565.64 1444.7117

Heat Transfer Coefficient vs Temp Diff

140000

120000

100000

80000

60000

40000

20000

0
76.5 77 77.5 78 78.5 79 79.5

Figure 4 Heat Transfer Coefficient vs Temp Diff

 Heat Transfer Coefficient vs Temp Diff
1600

1400

1200

1000

800

600

400

200

0
76.5 77 77.5 78 78.5 79 79.5

Figure 5 Heat Transfer Coefficient vs Temp Diff

3.7 Sample Calculations:

(m ∗ 𝐶𝑝 (𝑇𝑖𝑛 − 𝑇𝑜𝑢𝑡 ))
Φ=
𝐴𝑠𝑢𝑟𝑓
𝐾𝑔⁄
𝑚 = 0.033233 𝑠
𝑇𝑖𝑛 = 27.9 𝑜𝐶

𝑇𝑜𝑢𝑡 = 32.6 𝑜𝐶

𝐴𝑠𝑢𝑟𝑓 = 0.00454 𝑚2

𝐶𝑝 = 4200
32.6 − 27.9
Φ = (0.033233) ∗ 4200 ∗ = 144499 𝑊⁄𝑚2
0.00454
Φ
U=
(𝑇𝑠𝑎𝑡 − 𝑇𝑠𝑢𝑟𝑓 )

12554
U= = 1722
115 − 31.1

(115 − 27.9) − (115 − 32.6)

𝑇𝑚 = = 84.72 𝑜𝐶
(115 − 27.9)
ln ( )
(115 − 32.6)
3.8 Discussion

The experiment was carried out, and we obtained the expected data and results. We found that
the behavior of heat flux and surface heat transfer coefficient changes in a non-linear way for
both film-wise and dropwise condensation. In both cases, as the temperature difference (Tsat
– Tsurf) increases, the heat flux and surface heat transfer coefficient first go up, reach a peak,
and then go down. While film-wise condensation shows a nearly curved pattern, dropwise
condensation doesn't follow a specific trend. Comparing dropwise and film-wise condensation
results, we found that the heat flux and surface heat transfer coefficient are much higher for
dropwise condensation, almost twice as much. Dropwise condensation proves to be more
efficient because there's no resistance to heat transfer like in film-wise condensation. In
dropwise condensation, vapors turn into drops without forming a film, so there's little or no
resistance to heat transfer. The surface temperature depends on the temperatures of the
condensing apars and the cooling water. When the cooling water temperature is low, increasing
it boosts the heat transfer rate. However, as the cooling water temperature rises, the resistance
to heat transfer increases, leading to a decrease in heat flux and transfer coefficients. To
improve accuracy, the experiment could use better insulation materials, a vacuum to remove
air, precise power sources, and standardized operating conditions. Additionally, repeating the
experiment and using a clear experimental protocol can increase the reliability of the analysis.

3.9 Conclusion
The heat flux and heat transfer coefficient during film-wise condensation show a nearly
parabolic variation, whereas dropwise condensation does not follow a specific trend. Dropwise
condensation exhibits significantly higher heat flux and surface heat transfer coefficient
compared to film wise condensation, nearly doubling its effectiveness. As the temperature of
the cooling water rises, the resistance to heat transfer increases, resulting in a decrease in both
heat flux and transfer coefficients. Various errors, including human error, systematic errors,
and random errors, were identified in the experiment. Despite these challenges, the experiment
successfully achieved its objectives, as evidenced by the results obtained.