Role of substrate thermal conductivity and vapor pressure in dropwise condensation
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Energy & Fuels↗
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Designing slippery rough surfaces to enhance dropwise condensation of low surface tension fluid
Enhancing low surface tension liquid condensation is critical for achieving high energy efficiency and reducing the size of thermal energy systems. Extensive research has focused on promoting dropwise condensation of these liquids using state-of-the-art coatings on plain surfaces. However, maintaining dropwise condensation with low surface tension fluids is challenging due to rivulet formation, resulting in wetted tails that transition to filmwise condensation at elevated heat fluxes. Here, to address this issue, we uncover the role of surface structures and surface chemistry in the dropwise condensation of low surface tension ethanol on slippery rough surfaces (SRS). High-performance dropwise condensation has been achieved on slippery microchannels grafted with perfluoropolyether. The SRS uniquely facilitates rapid lateral droplet removal, enabling faster directional droplet shedding without rivulet formation. The resulting higher droplet removal frequency on SRS leads to heat transfer coefficients 100 % and 500 % higher than conventional dropwise and filmwise condensation on plain surfaces, respectively. Our findings uncover the pivotal role of rapid droplet removal through slippery microchannels in sustaining dropwise condensation of low surface tension liquids. This study introduces a new paradigm for promoting dropwise condensation using engineered SRS that incorporates surface structure and surface chemistry. The work will provide fundamental design guidelines to design efficient and compact condensers that use costly or flammable low global warming potential refrigerants in future refrigeration systems.
Dropwise condensation↗
Composite Structured Surfaces for Durable Dropwise Condensation
Dropwise condensation of steam on hydrophobic substrates has a 10X higher heat transfer coefficient compared to filmwise condensation. To promote dropwise condensation, low surface energy hydrophobic coatings (polymers) are typically utilized. The low intrinsic thermal conductivity (k < 1 W/(m · K)) of polymers, coupled with high heat transfer coefficient of dropwise condensation (100 kW/(m 2 · K)), necessitates that the coating be thin (< 1µm) in order to avoid reducing the overall heat exchanger conductance. However, thin polymeric films easily degrade. The two opposing requirements result in the need for optimization between the durability (thick coating) and the heat transfer (thin coating). To enable high thermal conductivity in thicker coatings, we develop metal-polymer structured surfaces. By using porous structures as inter-connected heat-conducting backbones that are filled with hydrophobic materials, we enable tuning of the coating effective thermal conductivity and surface energy. Three metal structures were studied; micro/nanowires, inverse opals, and sintered spheres. Heat transfer performance was calculated using three-dimensional finite element method simulations with two distinct boundary conditions; convection at the walls and isothermal walls. Interestingly, the overall conductance shows up to 40% difference depending on the boundary condition used in calculating the composite coating effective thermal conductivity. We use our model to predict the heat transfer performance as a function of metal fraction by volume and by surface area for condensation. By coupling our thermal simulations with a previously verified analytical model for predicting wetting behavior on heterogeneous surfaces, we propose a regime map to predict dropwise-to-filmwise transition. Furthermore, our work not only forms a starting point for the development of durable dropwise condensing surfaces, it identifies important considerations needed for computing effective thermal conductivity of composites.
42 ENGINEERING↗
Robust silane self-assembled monolayer coatings on plasma-engineered copper surfaces promoting dropwise condensation
Dropwise condensation is well known to result in better heat transfer performance owing to efficient condensate/droplet removal, which can be harnessed in various industrial heat/mass transfer applications such as power generation and conversion, water harvesting/desalination, and electronics thermal management. The key to enhancing condensation via the dropwise mode is thin low surface energy coatings (<100 nm) with low contact angle hysteresis. Ultrathin (<5 nm) silane self-assembled monolayers (or SAMs) have been widely studied to promote dropwise condensation due to their minimal thermal resistance and scalable integration processes. Such thin coatings typically degrade within an hour during condensation of water vapor. After coating failure, water vapor condensation transitions to the inefficient filmwise mode with poor heat transfer performance. We enhance silane SAM quality and durability during water vapor condensation on copper compared to state-of-the-art silane coatings on metal surfaces. We achieve this via (i) surface polishing to sub-10 nm levels, (ii) pure oxygen plasma surface treatment, and (iii) silane coating integration with the copper substrate in an anhydrous/moisture-free environment. The resulting silane SAM has low contact angle hysteresis (≈20°) and promotes efficient dropwise condensation of water for >360 hours without any visible sign of coating failure/degradation in the absence of non-condensable gases. We further demonstrate enhanced heat transfer performance (≈5-7× increase over filmwise condensation) over an extended period of time. Surface characterization data post-condensation leads us to propose that in the absence of non-condensable gases in the vapor environment, the silane SAM degrades due to reduction and subsequent dissolution of copper oxide at the oligomer-substrate interface. The experiments also indicate that the magnitude of surface subcooling (or condensation rate) affects the rate of coating degradation. Finally, this work identifies a pathway to durable dropwise promoter coatings that will enable efficient heat transfer in industrial applications.
42 ENGINEERING↗
Promotion of dropwise condensation of ethyl alcohol, methyl alcohol, and acetone by polytetrafluoroethylene
Coating condensing surfaces with thin layer of nonpolar Teflon results in dropwise condensation of polar organic vapor. Greater heat transfer coefficients are produced increasing effectiveness of condensing system. Investigation shows that vapors with strong dipole moment tend to condense dropwise.
Kirby, C. E.↗
Sustainble dropwise condensation enabled ultraefficient heat pipes
Heat pipes play a critical role in determining the operations, safety, and energy efficiency of electronics. The main focus to improve the heat pipe performance is on the evaporator design or wicking structures. However, the intrinsic limitation comes from the condenser, which is fundamentally constrained by inefficient filmwise condensation (FWC). In this study, we successfully achieved a peak effective thermal conductivity (k eff ) of ~140 kW/(m·K) on widely used groove heat pipes by implementing sustainable dropwise condensation (DWC) and integrating with enhanced evaporator. To better understand the working mechanisms of the ultraefficient heat pipe, both the evaporator and condenser of the heat pipes have been modified accordingly. Our results show that up to 296% enhancements on the k eff can be achieved under various inclination angles by only inducing DWC in the condenser section. The drawback of temperature fluctuations induced by DWC in smooth heat pipes appears to be effectively solved using the grooves-wicking structure. Furthermore, by integrating the nanostructured evaporator, the k eff of the heat pipe can be boosted up to 517% compared to conventional groove heat pipes. This study, for the first time, demonstrates the huge potential of engineering both the condenser and evaporator simultaneously in developing ultraefficient heat pipes.
42 ENGINEERING↗
Promotion of dropwise condensation of ethyl alcohol, methyl alcohol, and aceton by polytetrafluoroethylene
Heat transfer coefficients for dropwise condensation of organic liquids on Teflon
Kirby, C. E.↗
Limits of dropwise condensation heat transfer on dry nonwetting surfaces
Not Available
Hatte, Sandeep↗
The Effect of Adsorbed Volatile Organic Compounds on an Ultrathin Water Film Measurement
Using surface plasmon resonance imaging (SPRi), we have recently shown for the first time the existence of a monolayer water film between droplets during dropwise condensation. This study examines the effect of adsorbed volatile organic compounds (VOCs) on the ultrathin film measurement using SPRi. Further, the work presents the proper surface-treatment process that enables measurements of the ultrathin water layer during high-speed imaging of dropwise condensation at 3000 frame per second. In this study, two methods were applied for cleaning the surface (gold-coated glass)—(1) standard cleaning procedure (SCP) using acetone, isopropyl alcohol, and deionized water and (2) SCP followed by air plasma cleaning. This work discusses the effect of the cleaning procedures on surface roughness, contact angle, and surface chemistry using atomic force microscopy, optical microscopy, and an X-ray photoelectron spectroscope meter. The results showed that SCP before the SPRi is a proper surface-treatment method. The effect of adsorbed VOCs during dropwise condensation on a surface treated with SCP was measured to be 0.0025 (reflectivity unit), which was 70% smaller than the reflectance associated with a monolayer water film. The results of this work confirm a monolayer water film observation during the dropwise condensation, which has been reported before.
36 MATERIALS SCIENCE↗
Patterned Quasi-Liquid Surfaces for Condensation of Low Surface Tension Fluids
Extensive research concerns dropwise condensation of low surface tension fluids to promote energy efficiency and decarbonization in thermal energy systems. However, it is challenging as these fluids typically result in filmwise condensation. Drawing inspiration from the Namib desert beetle that enhances condensation through patterned wettability, conventional beetle-inspired surfaces excel in water condensation but flood when condensing low surface tension fluids. In this work, a patterned quasi-liquid surface is reported that achieves exceptional dropwise condensation of low surface tension fluids. The surface consists of alternating stripes with low surface energy, that is, a perfluoropolyether (PFPE) and fluorinated quasi-liquid surface (FQLS), that shows ultralow contact angle hysteresis for ethanol and hexane. Further, the PFPE stripes are slightly more slippery, acting as slippery bridges that accelerate droplet coalescence and removal. It is experimentally demonstrated that the striped PFPE-FQLS pattern exhibits a heat transfer coefficient 85%, 330%, and 550% higher than that of PFPE, fluorinated silane, and filmwise condensation, respectively. This study reveals that a high contact angle is desired to sustain dropwise condensation, irrespective of contact angle hysteresis. These findings provide a new paradigm for promoting the dropwise condensation of low surface tension fluids and offer valuable insights into surface design for energy sustainability.
36 MATERIALS SCIENCE↗
Enhanced condensation heat transfer using porous silica inverse opal coatings on copper tubes
Abstract Phase-change condensation is commonplace in nature and industry. Since the 1930s, it is well understood that vapor condenses in filmwise mode on clean metallic surfaces whereas it condenses by forming discrete droplets on surfaces coated with a promoter material. In both filmwise and dropwise modes, the condensate is removed when gravity overcomes pinning forces. In this work, we show rapid condensate transport through cracks that formed due to material shrinkage when a copper tube is coated with silica inverse opal structures. Importantly, the high hydraulic conductivity of the cracks promote axial condensate transport that is beneficial for condensation heat transfer. In our experiments, the cracks improved the heat transfer coefficient from ≈ 12 kW/m 2 K for laminar filmwise condensation on smooth clean copper tubes to ≈ 80 kW/m 2 K for inverse opal coated copper tubes; nearly a sevenfold increase from filmwise condensation and identical enhancement with state-of-the-art dropwise condensation. Furthermore, our results show that impregnating the porous structure with oil further improves the heat transfer coefficient by an additional 30% to ≈ 103 kW/m 2 K. Importantly, compared to the fast-degrading dropwise condensation, the inverse opal coated copper tubes maintained high heat transfer rates when the experiments were repeated > 20 times; each experiment lasting 3–4 h. In addition to the new coating approach, the insights gained from this work present a strategy to minimize oil depletion during condensation from lubricated surfaces.
Adera, Solomon↗
Switchable Wettability for Condensation Heat Transfer
Condensation proceeds as dropwise or filmwise depending on the wettability of the condensing surface. These two modes of condensation have disparate heat transfer coefficients, with dropwise often exceeding filmwise. This work reports a surface with switchable superhydrophilic to hydrophobic wetting behavior that can exhibit both modes of condensation. Relative to the highly-wetting state which yields filmwise condensation, the non-wetting state exhibits dropwise condensation and twice the heat transfer coefficient. Relevance to thermal management is additionally discussed.
Heat transfer↗
Novel solid-infused durable nonwetting surfaces for sustained condensation heat transfer enhancement
Here, in this article, we report novel nonwetting solid-infused surfaces that are easily fabricated using industrially widely adopted methods such as chemical etching or electrodeposition and exhibit sustained dropwise condensation performance durably than superhydrophobic and lubricant-infused surfaces. Solid-infused surfaces demonstrate fourfold larger condensation heat transfer coefficient and 25% better condensation effectiveness when compared to superhydrophobic surface and conventional filmwise condensation. Although the condensation heat transfer coefficient of lubricant-infused surface initially matches that of solid-infused surface, it is shown through durability studies that the wettability characteristic that underpins the performance of lubricant-infused surfaces degrades quickly with time as the lubricant depletes and lubricant-infused surface transitions to superhydrophobic surface. Solid-infused surface, on the other hand, retains its steadfast superior dropwise condensation effectiveness in the long run, overcoming the challenges of droplet pinning, surface inundation, cloaking, and lubricant depletion that eventually deteriorate condensation on conventional nonwetting superhydrophobic and lubricant-infused surfaces.
42 ENGINEERING↗
A Novel Steam Condenser with Loop Thermosyphons and Film-Forming Agents for Improved Heat Transfer Efficiency and Durability
In this DOE/NETL BAA program, Advanced Cooling Technologies, Inc. (ACT), with Suez Water Technologies & Solutions (Suez), developed film-forming amine coatings applied to condenser surfaces that incorporated loop thermosyphons to enhance steam surface condenser performance and efficiency for coal-fired power plants. The condensation phenomenon resulting from these coatings promotes efficient dropwise condensation without additional thermal resistance through the use of film-forming amines (FFA). The loop thermosyphon technology was being developed to supplant current pumped cooling water systems to reduce operations and maintenance issues, reduce energy use, and promote high thermal performance. Both of ACT’s advanced coating and loop thermosyphon technologies were developed for application to wet cooling and indirect dry cooling systems. Internal steam condensation and subsequent heat dissipation complete the thermodynamic power cycle used by power plant cooling systems. The successful 3-year project period delved into understanding the experimental performance gain using film-forming amines applied to flat and tubular condenser surfaces under realistic operating conditions. The performance gain was used to create a technoeconomic analysis to more clearly understand the market value for power plants using FFA coatings to achieve dropwise condensation on condenser surfaces. A tall (50 ft.) loop thermosyphon was designed, fabricated, and tested to optimize the performance characteristics by tuning the working fluid charge and determining the temperature drop across the loop at different heat loads. Commercialization opportunities were explored to transition the loop thermosyphon work into the building HVAC market.
20 FOSSIL-FUELED POWER PLANTS↗
Technoeconomic Benefits of Film-Forming Amine Products Applied to Steam Surface Condensers
In a conventional Rankine cycle, the majority of power plants employ surface condensers that use pumped cooling water to reject heat from the cycle. In such cases, heat rejection occurs in a shell and tube heat exchanger by film-wise condensation of low-pressure steam on stainless steel, titanium, brass, or copper-nickel tubing. To improve the thermal performance of steam surface condensers, a replenishable film-forming substance (FFS) can be ap-plied to the condenser tubing to promote efficient dropwise condensation. Conventionally, film-forming amine prod-uct (FFAP) coatings protect boiler surfaces from oxidative corrosion, which substantially reduces the operation and maintenance costs. To quantify the technical and economic benefits of FFAP coatings applied to condenser tubing due to the promotion of dropwise condensation, a thermal resistance network model was established. Using a rep-resentative steam surface condenser, the improvements in thermal performance (overall heat transfer coefficient) and process parameters (net plant efficiency, cooling water flowrate, and turbine backpressure) were determined due to the enhancement in the condensation heat transfer coefficient. Experimentally measured condensation heat transfer coefficients for common condenser materials were compared with the modeling results and were found to be within attainable bounds. Lastly, the trend in total heat exchanger cost reduction is generalized to understand the trade-off between reduced surface area for heat rejection and increase in coating application costs for a re-plenishable coating system.
20 FOSSIL-FUELED POWER PLANTS↗
Technoeconomic analysis of thermoelectric power plant condensers with nonwetting surfaces
Not provided.
Energy & Fuels↗
Online collection of LC effluent as droplets for automatic injection into ICP-MS
A sample introduction technique was developed to allow for online, dropwise injection of effluent into a mass spectrometer (MS). This allowed for the coupling of chromatography systems that were not driven by pumps without altering the set-up or separation performance. This capability combined the benefits of coupling separation and measurement while also enabling accurate chromatographic evaluation that would generally be performed offline. The incorporation of a flowing rinse into the system made dropwise resolution possible for any liquid capable of forming drops under ambient conditions. The technique was demonstrated utilizing gas pressurized extraction chromatography (GPEC) and inductively coupled plasma-time-of-flight mass spectrometry (ICP-TOFMS) to illustrate the qualitative applications for rapid separation development and procedure evaluation. This method's quantitative applications were evaluated using single and double isotope dilution mass spectrometry (IDMS) with an external mass bias correction to measure analytes across entire elutions including volumes as small as single drops. In conclusion, the total neodymium values afforded by both single and double IDMS were within the uncertainty of the calculated value for evaluation of full elution peaks and for most of the single drops analyzed that reached above 10k cps Nd-144.
GPEC↗
Enhancing Steam-Side Heat Transfer via Microdroplet Ejection using Inorganic Coatings
During condensation of water on a superhydrophobic nanostructured surfaces, droplets coalesce and jump (droplet ejection) due to the release of excess surface energy. Meticulously designed nanostructured surfaces or coatings capable of droplet ejection can enhance heat transfer performance by easy removal of droplets during condensation. In the present work, the capabilities of the Nelumbo droplet ejection coatings technology currently used in commercial heat exchangers are explored and optimized for materials and conditions relevant to steam condensers. Specifically, this includes (1) adapting and optimizing the procedures and chemistries to deposit droplet ejecting coatings on materials used in the steam condenser, (2) testing of the heat transfer, durability, and fouling of the fabricated coatings under a variety of steam condenser relevant conditions, and (3) modeling of the impact of droplet dynamics and interfacial properties on heat transfer in steam condensers. We experimentally demonstrated that at low supersaturation conditions (S~1.02), developed superhydrophobic nanostructured surface gives a 40% higher peak heat transfer flux and a 17% higher peak overall heat transfer coefficient (U) with droplet ejection mechanism compared to the dropwise condensation mechanism on the same nanostructured surface. Though the experimentally observed droplet ejection mechanism was short-lived (~3 min) due to the limitation of the chiller to maintain a constant supersaturation condition in fabricated steam condenser. And large variations in water inlet temperature (+ to - 2 degrees C) caused flooding of nanostructure (Wenzel state) at higher supersaturation (S > or = 1.12). This is an important finding because typical supersaturation levels in field operation are over 1.8 and as such, either the flooding potential for these materials should be improved or operation at lower supersaturation may be required to maximize heat transfer efficiency. If supersaturation conditions can be maintained reliably in the steam condenser in addition to droplet ejection mechanism during condensation, this could provide a potential 2% reduction in water flow rate which equates to a savings of over 3900 gallons of water per minute for a 500 MW steam turbine and over $0.3MM savings annually given a 0.02 cent marginal water withdrawal cost. It is also worth noting that these savings are based on improvement of droplet ejection coatings over coatings capable of performing consistent dropwise mechanism in in-field surface condensers. Savings due to the droplet ejections coatings when compared to bare substrates could be much higher. Additionally, the present work provides the importance of steam condenser operating conditions and insights into the challenges in modeling the condensing droplet dynamics on surfaces.
20 FOSSIL-FUELED POWER PLANTS↗