Condensation Heat Transfer Enhancement Research Articles

Optimization of Wavy Geometries for Enhanced Condensation Heat Transfer on Vertical Plates: An Experimental Study

In this study, macro-scale wavy geometries are used to enhance condensation heat transfer on vertical plates. Three wavy plates with different amplitudes (3.33mm, 4.17mm, and 5.56mm) were compared to a flat plate over a temperature difference range of 12K to 50K. For each plate configuration, heat transfer coefficient (HTC), enhancement factor (EF), heat flux (q), and Reynolds number (Re) were measured. Several studies have demonstrated that wavy surfaces offer better performance than flat surfaces, with the highest performance showing up for the 4.17 mm amplitude plate (Wave-2). At higher temperature differences, this optimal configuration achieved enhancement factors up to 1.31. As a result of the study, Reynolds numbers for the largest amplitude plate were 2.4 times higher than for the flat plate, indicating that increasing wave amplitude does not necessarily result in better heat transfer. These findings provide valuable insights for optimizing heat exchanger design in various industrial applications, offering a practical and cost-effective approach to improving falling film condensation heat transfer efficiency.

High-Efficiency Condensation Heat Transfer Interfaces Based on Superwetting Copper Microgroove/Nanocone Structure.

Utilizing superhydrophobic micro/nanostructures to enhance condensation heat transfer (CHT) of copper surfaces has attracted intensive interest in recent years due to its significance in multiple industrial fields including nuclear power generation, thermal management, water harvesting, and desalination. However, superhydrophobic surfaces have instability risk caused by microcavity defect-induced vapor penetration and/or hydrophobic chemistry destruction. Here, we report a superwetting copper hierarchical microgroove/nanocone (MGNC) structure strategy that can realize high-efficiency CHT over a whole range of surface subcooling. By regulating groove width, fin width, groove depth, and nanostructure growth time, we obtain the optimal MGNC structure, where the CHT coefficient is 121% and 107% higher than that of hydrophilic flat surfaces at surface subcooling of 2 and 15 K, respectively. Such remarkable enhancement can be ascribed to the synergy of three interface effects: more nucleation sites for phase-change energy exchanging, thinner condensate films for reducing thermal resistance, and parallel microchannels for timely drainage. Compared with superhydrophobic strategies, our strategy not only can be mass-producible but also has other inherent advantages: no microcavity-induced performance failure risk as well as being free of chemistry modification, which makes the fabrication process simpler and more economic. Hierarchical micropillar/nanocone structure is also fabricated as the contrast sample for highlighting the superiority of the superwetting MGNC structure in enhancing CHT. This work not only enriches research systems of superwettability surfaces but also helps develop high-performance chips' cooling devices and explore more potential applications.

Experimental Investigation of Large-Scale Vertically Coated Tubes for Enhanced Air–Steam Condensation Heat Transfer

Non-condensable gas plays a significant role in steam condensation, primarily by reducing heat transfer efficiency. Enhanced condensation heat transfer in the presence of non-condensable gas is crucial for improving thermal efficiency, reducing energy consumption, and lowering costs. However, experimental studies on applying coatings to enhance condensation heat transfer in large-scale vertical outer tubes with non-condensable gas are scarce. This study investigates the condensation heat transfer performance of vertical stainless steel- and brass-coated tubes compared to their bare counterparts at different air concentrations (0.4, 0.3, 0.15, and 0.08). All tubes have an outer diameter of 19 mm and an effective length of 1080 mm. Visualizations reveal that condensate flow rates as high as 0.5 m/s on bare tubes cause significant disturbances to the diffusion layer. At various air concentrations, the maximum condensation heat transfer coefficient of the coated stainless steel tube exhibited increases of 22.2%, 11.9%, 4.2%, and 19.6% compared with the uncoated stainless steel tube. Similarly, the maximum condensation heat transfer coefficient for the coated brass tube showed significant increases of 58.9%, 53.5%, 68.0%, and 70.7% compared with the uncoated brass tube. Notably, the enhancement effect on heat transfer performance is more pronounced when the same type of modified surface is applied to the brass tube compared with the stainless steel tube.

A separation column for liquid mixture based on phase transform: Experiment and simulation

The concentric internally heat-integrated distillation column (HIDiC) has advantages of low energy consumption and high thermodynamic efficiency. However, its drawbacks of limited heat transfer area, complex internal structure, and large number of control parameters hinder its widespread industrial applications. To solve these challenges, in this work a novel sleeve-like concentric heat integrated separation column, namely temperature-controlled phase change column (TCPC), was developed to separate liquid mixtures in a more effective and energy-saving way with reflux section being moved and trays being replaced with spiral corrugation blades. The comprehensive performances of TCPC in ethanol–water system was firstly evaluated by experiments. The results showed that TCPC performs well in ethanol/water separation due to the internal spiral corrugation significantly reducing the vapor–liquid contact in separation section. Meanwhile, compared to the concentric HIDiC, TCPC has a higher total heat transfer coefficient due to the larger heat transfer area. Computational fluid dynamics simulation reveals the internal design of TCPC inducing secondary vortices of the vapor, enhancing condensation heat transfer and separation efficiency. Further, increasing mass flow rate within a certain range would enhance the comprehensive performance factor and lead to more effective separation.

Numerical Investigation of Air-Steam Condensation in a Vertically Enhanced Tube with Concave and Convex Surfaces

Condensation heat transfer enhancement technology is an important problem for heat exchangers. The air-steam condensation inside a vertically enhanced tube with concave and convex surfaces is analyzed numerically, and the effects of relevant parameters on thermohydraulic performance are discussed. The numerical results show that the drop in steam and temperature between the inlet and outlet is improved by 53.8% and 96.8%, respectively, compared with smooth tubes. In the condensation process, the noncondensable gas accumulates near the wall, which leads to the deterioration of condensation. The structures of concave and convex surfaces disrupt the boundary layer flow and noncondensable gas film and promote flow mixing, leading to enhanced condensation heat transfer. All the numerical results provide guidance values for heat transfer enhancement technology in the applications of condensers.

Deep Learning Enabled Comprehensive Evaluation of Jumping-Droplet Condensation and Frosting.

Superhydrophobicity-enabled jumping-droplet condensation and frosting have great potential in various engineering applications, ranging from heat transfer processes to antifog/frost techniques. However, monitoring such droplets is challenging due to the high frequency of droplet behaviors, cross-scale distribution of droplet sizes, and diversity of surface morphologies. Leveraging deep learning, we develop a semisupervised framework that monitors the optical observable process of condensation and frosting. This system is adept at identifying transient droplet distributions and dynamic activities, such as droplet coalescence, jumping, and frosting, on a variety of superhydrophobic surfaces. Utilizing this transient and dynamic information, various physical properties, such as heat flux, jumping characteristics, and frosting rate, can be further quantified, conveying the heat transfer and antifrost performances of each surface perceptually and comprehensively. Furthermore, this framework relies on only a small amount of annotated data and can efficiently adapt to new condensation conditions with varying surface morphologies and illumination techniques. This adaptability is beneficial for optimizing surface designs to enhance condensation heat transfer and antifrosting performance.

Wettability patterning of titanium surfaces through pulsed laser melting for enhanced condensation heat transfer

Wettability engineering of different surfaces has been in the spotlight for the last few decades for enhanced condensation heat transfer in various applications. In this study, we experimentally investigated the water vapor condensation on a wettability-tailored Titanium-based (Ti-6Al-4V) grade 5 alloy. We utilize the microsecond laser to texture the surface by melting at various scanning speeds to realize a wide range of scalable surface structures. We further render these surfaces hydrophobic through chemical vapor deposition of silane at atmospheric pressure. Further water vapor condensation experiments are performed on these surfaces. The results show that the increased surface roughness due to laser-based melting altered the surface wettability of the Ti-surface and made it hydrophilic, exhibiting water drop contact angles ranging between 18° and 56° for the scan speeds between 25mm/s and 50 mm/s, respectively. The vapor deposition of silane on laser-melted Ti-surfaces lowered its surface energy and made them hydrophobic, showing contact angles of water drop up to ~106° specifically at lower scan speeds (~ 25 mm/s). Finally, the vapor condensation experiments showed an enhanced amount of condensed water collection with dropwise mode compared to the bare Ti surface due to a change in the wetting nature altered by laser melting.

Entropy Generation of R513A Condensation Flow Inside the Horizontal Microfin Tubes

Abstract It is widely acknowledged that the pressure drop increases with enhanced heat transfer in heat exchanger tubes, and entropy generation analysis serves as an effective method to comprehensively evaluate heat transfer and pressure drops. This paper conducts experimental research on in-tube condensation heat transfer using refrigerants R513A and R134a in six test tubes, comprising both smooth and microfin tubes with outer diameters of 9.52 mm and 12.7 mm, respectively. The microfin tubes are available in two types, with 60 and 65 fins, respectively, and a helix angle of 18 deg. The experimental conditions included mass fluxes of 50–250 kg/m2 s and condensation temperatures of 35 °C, 38 °C, and 40 °C. The findings indicate that replacing R134a with R513A is feasible. The 9.52 mm tube exhibits superior overall heat transfer performance compared to the 12.7 mm tube, and the 60-fin microfin tube outperforms the 65-fin tube in terms of heat transfer efficiency. This suggests that microfin tubes with smaller diameters and an optimal number of fins are more effective in enhancing condensation heat transfer performance.

Enhancing the vertical downward condensation heat transfer of a plate heat exchanger by electrochemical etching

This research employed electrochemical etching to generate microscale roughness on a plate heat exchanger (PHE) thereby enhancing condensation heat transfer in a vertical downward flow. The effects of the mass flux, vapor quality, heat flux, saturation temperature and microscale surface roughness on the condensation heat transfer coefficient (HTC) and frictional pressure drop (FPD) of R-513a flowing through a PHE was experimentally investigated. Experimental measurements were made under various heat fluxes of 5–15 kW/m2, mass fluxes of 60–80 kg/m2s, saturation temperatures of 40–50 °C, and mean vapor qualities of 0.1–0.7. HTC increased by up to 28, 26, 74, and 32.5 % as the heat flux, mass flux, average quality, and microscale surface roughness were respectively increased, but decreased by 19 % with the saturation temperature. FPD increased as the mass flux and average vapor quality increased, whereas it was reduced as the refrigerant saturation temperature increased. In contrast, the heat flux had little to no influence on FPD. Correlations for predicting the Nusselt number and friction factor were postulated by considering influential dimensionless numbers during heat transfer. Maximizing the Nusselt number and thermal performance factor was ultimately resolved using a multi-objective genetic algorithm to find a Pareto front solution. Consequently, the optimal surface roughness was found to be 9.94 μm.

Experimental study on enhancement condensation heat transfer in tube by foam metal in presence of non-condensable gas

Condensation heat transfer in tube is widely applied in industrial production, and the heat transfer process is often weakened by non-condensable gas (NCG) in actual production. Enhancing condensation heat transfer is beneficial to improve production efficiency, which has always been a hot topic in current research. Foam metal material with large specific surface area and good thermal conductivity is an ideal material to enhance heat transfer. In order to study enhancement heat transfer effect and optimize structure of foam metal, this paper investigated condensation heat transfer in tube strengthened by foam metal in presence of NCG experimentally. Section shape of foam metal is annular, and the pores per inch (PPI) of foam metals is 10, 15, 20 respectively. The effects of PPI value, steam/air mixture mass flow, and NCG mass fraction on heat transfer coefficient (HTC) and flow resistance are studied. The results reveal the following: (1) Compared with smooth tube, the foam metal enhances heat transfer significantly, and HTC increases by 1.5-2.3 times. (2) At same steam/air mixture mass flow, 10PPI foam metal tube has the highest HTC compared to others. (3) With increase of NCG mass fraction and PPI value, pressure drop increases and the HTC decreases. Based on experimental data, pressure drop and HTC correlations are developed. This paper provides an important technical basis for foam metal material application in enhancement heat transfer area.

Condensation heat transfer enhancement through durable, self-propelling fluorine-free silane-treated anodized surfaces

When two or more adjacent droplets coalesce, excess surface energy is generated, which can be converted into the kinetic energy of the merged droplet through a suitable nanostructure and the superhydrophobicity of the surface.

Study of filmwise condensation heat transfer enhancement by removal of condensate using wettability difference

Study of filmwise condensation heat transfer enhancement by removal of condensate using wettability difference

Numerical study on dominant oscillation frequency of unstable steam jet under heaving condition

With its advanced efficiency in heat transfer, the steam direct contact condensation method is now extensively employed in many areas. The pressure oscillation characteristics of unstable steam jets under heaving conditions were investigated numerically in this study. The dominant oscillation frequency gradually rose with the decrease of the heaving period and the increase of the heaving amplitude. The dominant oscillation frequency under the heaving condition was higher than that under the static condition, with a maximum increase of 27.4%. The inertia and condensation dominated the evolution of steam bubbles at the necking stage under heaving conditions. With the decrease of the heaving period and the increase of heaving amplitude, the additional force induced by heaving movement increased, contributing to the condensation heat transfer enhancement. A dimensionless correlation predicting the dominant oscillation frequency at a low flow rate under heaving conditions was fitted, and the maximum error was within ±6.2%.

On the effect of static and dynamic contact angles on humid air condensation heat transfer

Surface modification is a widely utilized technique for enhancing condensation heat transfer. Two main properties of surfaces in manipulation of condensation heat transfer are the contact angle and contact angle hysteresis. This study focuses on the influence of contact angle (CA) and contact angle hysteresis (CAH) on humid air condensation. For this, hydrophilic and hydrophobic surfaces with varying CA and CAH values were fabricated and tested in a humidity-controlled climate chamber at different relative humidity levels. Three hydrophilic surfaces samples with a contact angle of approximately 70° and CAH values of 10°, 20°, and 42° were tested. Two hydrophobic surfaces with a contact angle of approximately 110° and CAH values of 21° and 39°were also prepared as well as a hydrophobic surface with a contact angle of 96° and a CAH of 43°. The role of CA and CAH in different stages of condensation cycle was investigated. Our findings show that while CA plays the main role in droplet nucleation, CAH has a significant impact on droplet coalescence and departure. Increasing CAH while keeping CA constant has a negative effect on condensation heat transfer in all wettability levels. However, the relationship between changes in CA while keeping CAH constant does not have the same trend in the condensation heat transfer performance for every case. Changing CAH for lower CAH values led to a greater impact on enhancing condensation heat transfer than higher values. Moreover, increasing CAH on hydrophobic surfaces had a more significant effect than on hydrophilic surfaces. Additionally, decreasing CAH had a more pronounced effect on improving condensation heat transfer than increasing CA. The findings emphasize on the importance of considering both the contact angle (CA) and contact angle hysteresis (CAH) in the surface design to have the optimum condensation heat transfer performance.

A mechanistic model for acoustically enhanced condensation heat transfer and pressure drop

Enhancing low-quality condensation where thermal resistance is the highest is critical for size reduction and efficiency improvements for many power generation, HVAC&R, and chemical processing applications. Recently, acoustic actuation has been shown to enhance low-quality condensation by ∼30% by introducing a sound wave that oscillates between the condenser headers and resonates within the tube, agitating the liquid-vapor interface and significantly altering the distribution of the liquid phase towards the end of condensation, thereby increasing the heat transfer rate. This paper presents a multiple flow-regime model to predict the pressure drop and heat transfer during acoustically actuated condensation based on hydrodynamic changes induced by forced oscillation. Experimental results for R134a flowing through a horizontal tube across the entire quality range for mass fluxes ranging from 120 to 235 kg m−2 s−1, actuation frequencies from 2 to 20 Hz, header volumes from 150 to 1000 mL, and wall-to-refrigerant temperature differences ranging from 6 to 12 K are used for the development of the models. Enhancement mechanisms are discussed and heat-and-momentum analogy-based correlations are developed to accurately predict actuated and unactuated condensation pressure drop and heat transfer data simultaneously within 23% and 7% on average, respectively.

Numerical investigation of the gravity effect on two-phase flow and heat transfer of neon condensation inside horizontal tubes

The condensation flow and heat transfer characteristics of cryogenic neon inside horizontal tubes with diameters of 1 mm and 2 mm were numerically investigated. The mass flux ranged from 20 to 187 kg/(m2·s) for gravity levels includes zero gravity, Lunar gravity, Martian gravity, and Earth gravity. The effects of gravity on the condensation flow pattern, local condensate film distribution, and local and global heat transfer were analyzed in detail. The gravity effect on the condensation heat transfer showed three states, including enhancement, deterioration and gravity-independence, which were mainly determined by the mass flux and vapor quality. Under normal gravity, the condensation heat transfer coefficients increased with increasing mass flux and decreasing tube diameter. Under low mass flux, the cryogenic neon underwent enhanced condensation heat transfer under zero gravity and reduced gravity in the high vapor quality region but deteriorated condensation heat transfer in the low vapor quality region. By increasing the mass flux, the gravity effect was effectively suppressed, which resulted in gravity-independent behavior of condensation heat transfer in the high vapor quality region. The gravity effect significantly affected the liquid film distribution in the condensation process, with a more uniform distribution of the liquid film appearing along the circumferential direction as the gravity level decreased. However, due to the low surface tension of the deep cryogenic fluid, the condensation interface was more prone to flow instability under reduced gravity levels.

A Multiscale Strategy for Constructing Finned Microporous Superhydrophobic Surface for Highly‐Efficient Condensation Heat Transfer Enhancement Enabled by Lifespan Regulation of Droplets

AbstractSpontaneous droplet jumping on micro‐/nano‐structured superhydrophobic surfaces has been exploited as an efficient means for enhancing steam condensation heat transfer. However, the good performance of such surfaces quickly decays with raising the degree of subcooling, due to the mismatch between the characteristic length scales and droplet sizes when they grow up. Herein, a novel strategy for multiscale droplet regulation is proposed by combining sub‐millimeter fin structure with a hierarchical microporous superhydrophobic surface. A superior condensation heat transfer performance is attained on such hierarchical superhydrophobic finned tube (F‐SHB), in comparison to the baseline case of superhydrophobic non‐finned (SHB) tube under well‐controlled test conditions. Although the droplet jumping is not as vigorous as that on the SHB tube, the finned geometry of the F‐SHB tube leads to a condensation heat transfer enhancement even under high degrees of subcooling up to 36 K, because of the accelerated departure of large droplets by imposing Laplace force gradient in the presence of V‐shaped sub‐millimeter fins. This multiscale enhancement strategy is shown to enable a cascading regulation over the entire lifespan of condensate droplets. The fabrication of F‐SHB tubes is facile and easy to be scaled up, showing great potential in practical steam condensation applications.

Low-pressure steam dropwise condensation on durable PFA-coated horizontal tube: Droplet dynamics in active region

The performance of low-pressure steam condensers is vital to the thermal energy utilization efficiency of the power cycle, refrigeration, heat pump, and seawater desalination systems. Dropwise condensation demonstrates better heat transfer performance than traditional filmwise condensation, and its performance is determined by the condensate droplet dynamic behaviors on hydrophobic surfaces. However, the droplet dynamics behavior on the horizontal tube has not been adequately investigated. In this study, a durable PFA-coated copper tube is achieved to sustain stable dropwise condensation at the vapor pressure ranging from 5 to 100 kPa. By optical observation of condensation on the horizontally oriented tube, the droplet dynamic characteristics and the influence of vapor pressure on the droplet dynamics are examined. We show that an ‘active droplet region’ (ADR), which is characterized by frequent droplet shedding and surface renewal promoting more active nucleation, growth, and departure of droplets, exists along the tube circumference. As a result of the varying droplet dynamics, a skew-normal distribution of sliding droplet numbers presents along the tube circumference. The droplets departing within ADR account for 80% of the total departure droplets. Then, the effect of steam pressure on the droplet dynamics behavior in ADR is studied systematically. The average sweeping frequency of droplets under steam pressure of 100 kPa increases by -122% more than that under steam pressure of 5 kPa. The growth rate of droplets and migration speed improve with steam pressure. Thus, the evolution rate of the transient size distribution becomes rapid as the vapor pressure increases. Taking vapor pressure and circumferential angle into consideration, a semi-empirical model for the prediction of condensate droplet departure radius on a horizontal tube is proposed, of which the standard deviation can be reduced to less than 15%. These findings and insights into droplet dynamic behaviors on PFA-coated hydrophobic horizontal tube are of great significance for the novel surface design strategy for the enhancement of dropwise condensation heat transfer.

When coalescing droplets jump: A unified energy conversion model incorporating droplet size and surface adhesion

Jumping-droplet condensation pushes the boundary of condensation heat transfer by enabling microdroplet shedding via coalescence-induced droplet jumping. The latter is empowered by surface-to-kinetic energy conversion. Regardless of extensive studies of droplet jumping on ideally non-wetting surfaces, a quantitative description of droplet jumping from realistic surfaces remains a challenge due to limited insight into the complex energy conversion process that is strongly coupled with droplet–droplet and droplet–substrate interactions. Here, we use a three-dimensional (3D) pseudopotential multiphase multiple-relaxation-time lattice Boltzmann method (MRT-LBM) to simulate binary-droplet coalescence with various droplet sizes and surface wettability. Then, we developed a comprehensive and unified energy conversion model, derived by rigorously analyzing the dynamic droplet–surface interaction and quantifying the roles of droplet size scale, droplet size mismatch, and surface wettability. Our simulations capture coalescence and jumping dynamics of arbitrary-sized droplets on surfaces having various wettability and reveal the effect of droplet size and surface wettability. Validated by experiments, the energy model is then used to define the jumping/non-jumping boundaries for coalescing droplets on nanostructured surfaces. Our work demonstrates the key physics and a universal criterion governing self-propelled droplet shedding, key to the design of surfaces for enhanced condensation heat transfer, anti-frosting/icing, self-cleaning, and water/energy harvesting.

Effects of Numerical Schemes of Contact Angle on Simulating Condensation Heat Transfer in a Subcooled Microcavity by Pseudopotential Lattice Boltzmann Model

Various numerical schemes of contact angle are widely used in pseudopotential lattice Boltzmann model to simulate substrate contact angle in condensation. In this study, effects of numerical schemes of contact angle on condensation nucleation and heat transfer simulation are clarified for the first time. The three numerical schemes are pseudopotential-based contact angle scheme, pseudopotential-based contact angle scheme with a ghost fluid layer constructed on the substrate with weighted average density of surrounding fluid nodes, and the geometric formulation scheme. It is found that the subcooling condition destabilizes algorithm of pseudopotential-based contact angle scheme. However, with a ghost fluid layer constructed on the substrate or using geometric formulation scheme, the algorithm becomes stable. The subcooling condition also decreases the simulated contact angle magnitude compared with that under an isothermal condition. The fluid density variation near a microcavity wall simulated by pseudopotential-based contact angle scheme plays the role of the condensation nucleus and triggers “condensation nucleation”. However, with a ghost fluid layer constructed on the substrate or using geometric formulation scheme, the simulated fluid density distribution near the wall is uniform so that no condensation nucleus appears in the microcavity. Thus, “condensation nucleation” cannot occur spontaneously in the microcavity unless a thin liquid film is initialized as a nucleus in the microcavity. The heat flux at the microcavity wall is unphysical during the “condensation nucleation” process, but it becomes reasonable with a liquid film formed in the microcavity. As a whole, it is recommended to use pseudopotential-based contact angle scheme with a ghost fluid layer constructed on the substrate or use the geometric formulation scheme to simulate condensation under subcooling conditions. This study provides guidelines for choosing the desirable numerical schemes of contact angle in condensation simulation by pseudopotential lattice Boltzmann model so that more efficient strategies for condensation heat transfer enhancement can be obtained from numerical simulations.