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EXPERIMENTAL MANUAL
Table of Contents
Page
Table of Contents............................................................................................................................... i
List of Figures.iii
1.0
INTRODUCTION..................................................................................................................1
2.0
3.0
4.0
SUMMARY OF THEORY.....................................................................................................6
5.0
6.0
7.0
8.0
8.1 Warning........................................................................................................................18
8.2 Cautions.......................................................................................................................18
ii
List of Figures
Page
Figure 1
Figure 2
iii
1.0
INTRODUCTION
The use of steam both for power production 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 cold water in a condenser of generating station, hot water in a
heating calorifier, sugar solution in a sugar refinery and etc. During condensation very
high heat fluxes are possible and provided that the heat can be quickly transferred
from the condensing surface into the cooling medium, the heat exchangers can be
compact and effective.
Steam may condense onto a surface in two distinct modes, known as the Filmwise and
the Dropwise condensation. For the same temperature difference between the steam
and the surface, dropwise condensation is several times more effective than filmwise,
and for this reason the former is desirable although in practical plants, it seldom occurs
for prolonged periods.
The SOLTEQ Film & Dropwise Condensation Unit (Model: HE163) is designed to help
student to understand several key aspects in condensation topic, in particular the
process of filmwise and dropwise condensation. It allows students to visualize both
phenomena and perform a few experiments to demonstrate both concepts.
2.0
GENERAL DESCRIPTION
2.1
Unit Assembly
1
2
5
6
7
8
9
4
10
Figure 1: Unit Construction for Film & Dropwise Condensation Unit (Model: HE 163)
6. Separator
2. Indicators
7. Dropwise Condenser
3. Flowmeter
8. Filmwise Condenser
4. Discharge Valve
9. Coiled-Heater
5. Pressure Transmitter
2.2
Experiment Capabilities
x
x
x
x
2.3
Specifications
2.3.1 Steam Chamber
x
2.3.2 Condensers
x
2.3.5 Instrumentations
x
x
x
2.4
Overall Dimensions
Height : 800 mm
Width : 900 mm
Depth : 600 mm
2.5
General Requirements
Electrical
Water
: 230VAC/50Hz/25 Amp
: Continuous water supply (Min 10LPM @ 2-3 Bar)
3.0
3.1
3.2
3.3
3.4
Temperature Sensors
Five temperature sensors are installed and each lead has a label. There are
also 6 thermocouple wires installed. Ensure that all thermocouples and the
lead are in good condition.
The Film & Dropwise Condensation Unit requires a source of clean and
constant temperature (cold) water with flow approximately 4 - 5 LPM at 2 to 3
bar supply. The Film & Dropwise Condensation Unit comes with water inlet
valves to control the water flow rates. Connect the water supply to the coldwater inlet.
The Film & Dropwise Condensation Unit comes with two drain tubes; one for
the condenser and one for the vacuum ejector. They should be secured
properly so that it will not fall out during the experiment.
Commissioning Procedures
Push the reset button of the Earth Leakage Circuit Breaker (ELCB) inside the
control panel after the main power supply is switched on. The ELCB should be
kicked off, indicating that the ELCB is functioning properly. If not, have a
trained wireman to inspect the trainer for any electrical leakage. The ELCB
should be tested at least once a month. Switch on the main switch and check
the indicators. They should display the measurements of all respective
instruments. Fill the boiler chamber with distilled water from the bottom valve
until the water level is sufficient to fully cover the heater element. Switch on the
heater and observe the boiling. Then, slowly open the cooling water of both
film and dropwise condensers. The flow indicators should display the
respective flow rates. Switch off the heater, the unit is ready for use.
Note: Never operate the heater whenever the water level falls below the
heater element as this will permanently damage the heater.
4.0
SUMMARY OF THEORY
4.1
Mechanism of 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 comes in contact
with 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 heattransfer. This is called filmwise 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 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
(via coating). However, dropwise condensation is difficult to maintain in
industrial applications due to oxidation, fouling and degradation of coating, and
eventually film condensation occurs. Therefore, condenser designs are often
based on the assumption of filmwise condensation.
4.2
G y dx U l UX g
P l
(4.2-1)
g U l UX
PL
Gy y / 2
2
(4.2-2)
Figure 2:
The mass flow rate of film condensate at any point x for unit depth is;
U lXdy
Ul
g U l UX
Pl
Gy y / 2dy
2
(4.2-3)
Integrating;
U l g U l UX G 3
3P l
(4.2-4)
At the wall, for area (dx1) m2, the rate of heat transfer is as follows if a linear
temperature distribution is assumed in the liquid between the wall and the
vapor;
qx
k l dx 1
dT
dy
k l dx
y 0
Tsat Tw
G
(4.2-5)
U l g U l UX G 3
3P l
dm d
U l g U l UX G 2dG
Pl
(4.2-6)
Making a heat balance for dx distance, the mass flow rate dm times the latent
heat h fg must equal the q x from Eq. (4.2-5):
hfg
U l g U l UX G 2dG
Pl
k l dx
Tsat Tw
G
(4.2-7)
4 P l k l x Tsat Tw
ghfg U l U l UX
1/ 4
(4.2-8)
hx dx 1Tsat Tw k l dx 1
Tsat Tw
G
(4.2-9)
This gives
hx
kl
(4.2-10)
hx
U l U l UX ghfg k l 3
4 P l x Tsat Tw
1/ 4
(4.8-17)
4
hx
3
h dx
L x
U U UX ghfg k l 3
0.943 l l
P l LTsat Tw
(4.2-11)
1/ 4
(4.2-12)
However, for laminar flow, experimental data are about 20% above Eq. (4.212). Hence, the final recommended expression for vertical surfaces in laminar
flow is shown as Eq. (4.2-13):
N Nu
U U UX ghfg L3
hL
1.13 l l
P
kl
k
T
'
l
l
1/ 4
(4.2-13)
where U l is the density of liquid in kg/m3 and U X that of the vapor, g is 9.8066
m/s2, L is the vertical height of the surface or tube in m, P l is the viscosity of
liquid in Pas, k l is the liquid thermal conductivity in W/mK, 'T = T sat -T w in K,
and h fg is the latent heat of condensation in J/kg at T sat . All physical properties
of the liquid except h fg are evaluated at the film temperature T f = (T sat + T w )/2.
For long vertical surfaces the flow at the bottom can be turbulent. The
Reynolds number is defined as;
NRe
NRe
4m
4*
SDP l
Pl
4m
4*
WP l
Pl
(4.2-14)
(4.2-15)
N Nu
gU 2 L3
hL
0.4
0.0077 l 2 N Re
kl
Pl
(4.2-16)
Solution of this equation is by trial and error, since a value of N Re must first be
assumed in order to calculate h.
10
5.0
5.2
5.3
5.4
Temperature Reading
To read a particular flow, use the flow selector knob to select the desired
reading (FT1 or FT2).
Heater Setting
To turn on the heater, turn the heater switch to ON position. The power
supply to the heater is controlled by turning the potentiometer clockwise to
increase the value or anticlockwise to reduce the value. Use both coarse and
fine regulators to obtain the desired heating power.
The cooling water flowrate can be controlled by simply turning the valve
clockwise to reduce flow rate or turning the valve anti-clockwise to increase
flow rate.
11
6.0
EXPERIMENTAL PROCEDURE
6.1
6.2
12
6.3
Procedures:
1. Follow the basic procedure as written in section 6.1. Make sure that the
equipment is connected to the service unit.
Assignment:
13
6.4
To determine the filmwise heat flux and surface heat transfer coefficient at
constant pressure
Procedures:
Assignment:
14
6.5
To determine the dropwise heat flux and surface heat transfer coefficient at
constant pressure
Procedures:
Assignment:
15
6.6
Procedures:
Assignment:
1. Plot Surface Heat Transfer Coefficient vs. Temperature Difference (T sat T surf ) with the presence of air, for filmwise and dropwise condensation
respectively.
2. Plot Surface Heat Transfer Coefficient vs. Temperature Difference (T sat T surf ) with the presence of air and without presence of air in a single graph,
for filmwise and dropwise condensation respectively. Compare and
discuss the effect of air on heat transfer coefficients.
3. Describe the phenomena theoretically.
16
7.0
EQUIPMENT MAINTENANCE
7.1
7.2
Heater
Cool down the equipment before draining the water inside the glass vessel so
that the heater will not be overheated when there is no water inside the vessel.
Condenser
Make sure tap water used is free from any contamination to prevent blockage
inside the condenser.
17
8.0
SAFETY PRECAUTION
8.1
Warning
High voltages exist and are accessible in the control panel. Return the unit to
your supplier for any servicing.
8.2
Cautions
1. Never splash water to the control panel. This will cause body injury and
damage to the equipment.
2. Never use your bare hand to test the AC Power Supply. It may cause
hazardous injury.
18
APPENDIX A
EXPERIMENTAL DATA SHEET
Flow rate
(LPM)
qx
T sat
T surf
=
=
=
=
=
Power
(W)
Tin
(degC)
Tout
(degC)
Tsat
(degC)
Tsurf
(degC)
Tsat - Tsurf
(degC)
7P
(degC)
(W/m2)
U
(W/m2.K)
Flow rate
(LPM)
qx
T sat
T surf
=
=
=
=
=
Power
(W)
Tin
(degC)
Tout
(degC)
Tsat
(degC)
Tsurf
(degC)
Tsat - Tsurf
(degC)
7P
(degC)
(W/m2)
U
(W/m2.K)
Flow rate
(LPM)
qx
T sat
T surf
=
=
=
=
=
Power
(W)
Tin
(degC)
Tout
(degC)
Tsat
(degC)
Tsurf
(degC)
Tsat - Tsurf
(degC)
7P
(degC)
(W/m2)
U
(W/m2.K)
Flow rate
(LPM)
qx
T sat
T surf
=
=
=
=
=
Power
(W)
Tin
(degC)
Tout
(degC)
Tsat
(degC)
Tsurf
(degC)
Tsat - Tsurf
(degC)
7P
(degC)
(W/m2)
U
(W/m2.K)