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Condensation Inside Horizontal Tubes: State of The Problem and Analysis of Research Results

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15th Workshop on Transport Phenomena in Two-Phase flow, 2011

CONDENSATION INSIDE HORIZONTAL TUBES: STATE OF THE PROBLEM


AND ANALYSIS OF RESEARCH RESULTS

V.G. Rifert*, V.V. Gorin*, Barabash P.A.*, V.V. Sereda**


[email protected], [email protected], [email protected], [email protected]

* National Technical University of Ukraine “Kiev Polytechnic Institute”


**National University of Water Management and Nature Resources Use, Rovno, Ukraine

Key words: Heat transfer, Condensation, Smooth tube, Horizontal tube, Inside, Re-
view, Refrigerant

Abstract

This paper presents analysis of the study on in-tube condensation performed until 2010.
It is found that in all published studies has been measured only tubes with average perimeter
and heat transfer coefficients at certain length (minimum 0,5 m) during condensation inside
smooth tubes that did not provide sufficient data concerning the features of heat transfer dur-
ing condensation, namely impact of vapour quality, vapour velocity, heat flax, condensate
accumulation on heat transfer. The disadvantages of the existing methods of heat transfer re-
search, of experimental data presentation, and of design correlations are pointed out.

Introduction

Interest to investigation of hydrodynamics and heat transfer in condensing inside hori-


zontal tubes is permanently actual due to demand of improvement of the design of various
heat exchangers (condensers, film evaporators with horizontal tubes in water demineralizers,
heaters and condensers of power plants, heat pipes and thermosyphons).
In monographs [1] and [2], the experimental data of more than 60 works published be-
fore 1998 on condensation of vapors of different fluids inside smooth and finned tubes are
represented. In these works both analysis of the research methods nor comparison of experi-
mental and calculated data are given. In work [3], the calculations based on correlations de-
rived by various authors (seven references) are compared with the experiments on refrigerants
(6 types) and it is shown that some calculations disagree with the experiments by up to 100%
and more.
In works [4] to [8], the diagrams of phase flow patterns in condensing inside smooth
horizontal tubes are refined and taking into account the obtained data new design correlations
are proposed. They differ from those cited in [3] both by some complements in the dimen-
sionless complexes and by their exponents of power. These correlations also are not in a good
compliance with the experiments and, more importantly, there is neither conception of the
process nor substantiation of the represented design correlations.
In the work under consideration, the methods of heat transfer investigation, of represen-
tation of the experimental data, and of their comparison with the design correlations are ana-
lyzed.

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15th Workshop on Transport Phenomena in Two-Phase flow, 2011

Investigation methods

In all works beginning from [9] up to now ([8] is the last one known to the authors) the
method of investigation of heat transfer under condensation inside horizontal tubes is the
same and insignificantly differs only by diameters and lengths of the experimental sections,
number of the thermocouples to measure wall temperature (in some works heat-transfer coef-
ficients are determined by Wilson’s method, i.e., without measurement of wall temperature),
and the methods of surface cooling. The minimal length l of tested section took place in [10]
and equaled to 0.3 m. In other works l = 0.5 to 1.5 m. Wall temperature of tested tubes was
measured in three or four points around tube perimeter and in several cross-sections along the
length. Thus, in effect in these works perimeter-average heat-transfer coefficient α ϕ was
measured in specified points along the tube.
Schematic drawing of the experimental apparatus (Fig. 1) included evaporator 1, vapor
compressor 2, preliminary section of condensation 3 to create a certain vapor content x at the inlet
to tested section 4, condenser 5 to condense vapor downstream tested section 4, inspection sec-
tions 6, pressure and temperature gauges at the inlet and outlet of all condensation sections, and
condensate flow meters 7. In some works tested section had several subsections (minimal length
of each was 0.3 m) cooled by means of a separate water circuit.

1 – Evaporator
(water-cooled);
2 – Compressor;
3 – Pre-condenser (water-
cooled);
4 – Test section
(water-cooled);
5 – Post-condenser (water-
cooled);
6 – Sight glass;
7 – Mass flow meter;
p – Pressure tap;
T – Thermocouple.
Fig. 1. Schematic drawing of the experimental apparatus.

By setting small (0.1 to 0.2) changes in vapor content in tested section the authors sup-
posed that they measure heat-transfer coefficients for local specified values of G and x. Such
approach to the measurements and assessment of locality of α has the following disadvan-
tages.
The first disadvantage. To provide properly substantiated small variations in ∆х and G in
the experiments it is necessary to maintain heat flux density in the tested section decreasing as G
is decreasing and length of the tested section is growing under fixed ∆х. It follows from trivial
Gdhlv
correlation qmax = Δxmax . For example, with reference to R410A (hlv = 1.6·105 kJ/kg) and d
4l
= 8 mm at l = 1 m and ∆хmax = 0.1 the following takes place:
at G = 100 kg/m2/s qmax  2.5·103 W/m2;
and at G = 200 kg/m2/s qmax  5·103 W/m2.

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15th Workshop on Transport Phenomena in Two-Phase flow, 2011

Actual value of q in industrial condensers by several times exceeds 2500 W/m2. It means
that effect of q on α has not been virtually investigated.
The second disadvantage of the used method is connected with the first. In real heat ex-
changers with long tubes (4 to 9 m) at vapor inlet into the tube, where х > 0.7 to 0.5, heat-
transfer coefficients could be several times higher than at the end of the tube, where x → 0 .
Hence, heat flux q at the tube inlet is also significantly higher than at its end. As a result, be-
havior and rate of heat transfer either along the tube or depending upon variation in х in real
heat exchangers significantly differ from those obtained under condensation, when low values
of q are fixed.
The third uncertainty of existing methods of investigation lies in the following. Due to
impact of gravity on flow of condensate film virtually at х < 1 under all values of G conden-
sate drains along tube perimeter. When tested sections are longer than 0.3 m, ϕ-average heat-
transfer coefficients α ϕ vary even under negligible variations in G and x along tube length.
Therefore, depending upon the values of G, q, x, l, and physical properties of vapor the
values of heat-transfer coefficients estimated by the data based on the applied methods of
measurement can be substantially different.

Methods of experimental data presentation


In the majority of works the experimental data represent heat-transfer coefficient averaged
along the length of tested section as a function of x or G at the inlet of two-phase flow into the
section. In this case, with rare exception, there is lack of information on the heat fluxes or tem-
perature drop. Not numerous works [11] to [14], where the data on mean heat-transfer coeffi-
cients α are represented as a function of q or tabulated [11] by the values of q, xin at the inlet
and xout at the outlet of the tested tube, make an exception.
Functions α = f ( x, ρ w ) are correct (accurate) for analysis of the process only in the case
of homogenous flow, which is possible, when condensation occurs inside a tube (its vertical or
horizontal position is of no importance), in a definite section of the tube, where heavy entrain-
ment of condensate by vapor flow takes place, i.e., under high enough vapor velocity and high
amplitudes of condensate waves. Diagrams plotted as α = f ( x ) at various G and in the range
of х from 1 to 0 hardly explain the behavior of heat transfer. Under х = 1, at tube’s inlet conden-
sate film always flows in an annular mode and, if the velocity remains high enough to create
vapor friction significantly (by one order and more) exceeding gravity force, then it is quite
clear that the process rate is affected by film hydrodynamics (laminar, wavy or turbulent flow,
breakaway of condensate). Similarly to condensation inside vertical tube, the regularities of heat
transfer in this section correspond to the theory of film condensation by Nusselt [15] and Duck-
ler [16], from which it follows that heat transfer depends upon vapor velocity w (number Frv)
and heat flux (number Ref) corrected by an impact of condensate exhaust (cross-sectional mass
flow) and entrainment of condensate on condensation rate (works [17] to [19]).
The main section with asymmetric flow of condensate that sometimes prevails along the
tube is even more complicated. In this case mean coefficient of heat transfer α in characteris-
tic section of tube is determined by the readings of several (three or four) thermocouples in-
stalled in different points of tube’s perimeter and along tested section with knowing nothing
on local heat fluxes in different ϕ around tube’s perimeter. It results in extremely faulty in-
formation, because local α ϕ and respectively local qϕ in the upper cross-section of tube are

157
15th Workshop on Transport Phenomena in Two-Phase flow, 2011

much higher than in the lower one. It is reflected in works [12] and [19], where just local α ϕ
and qϕ were measured.
Under low G and х, neither impact of х nor unambiguous impact of G on α were ob-
served that is seen from the analysis of work [7] and demonstrated in Fig. 2. It is also clear, if to
keep in mind that in the region of condensation by Nusselt the heat transfer depends only upon
q (∆T) similarly to condensation in outer surface of horizontal tube.

1 – G=300 kg/(m2·s);

2 – G=250 kg/(m2·s);

3–G = 200 kg/(m2·s);

4 – G=175 kg/(m2·s);
5 – G=150 kg/(m2·s);
6 – G=125 kg/(m2·s);
7 – G=100 kg/(m2·s);

8 – G = 75 kg/(m2·s).
Fig. 2. α plotted against
х for condensation of R134a at
different G.

Development of design correlations and comparison of them with experimental re-


sults

Theoretical solution of the problem of condensation inside horizontal tubes was carried
out for two modes of two-phase flow: for the mode with prevailing impact of gravity force (in
the works this mode is called stratified) and for annular mode of phase flow, when gravity is
neglected.
In all works, for the stratified mode Nusselt’s correlation [15] derived for condensation
on outer surface of horizontal tubу is used:

⎛ λ 3ρ ( ρ − ρv ) ghlv ⎞
0.25

α st = 0.725 ⎜ l l l ⎟ , (1)
⎝ μl d ΔT ⎠

with various empirical corrections taking into account availability of stream in the lower part
of tube, where heat transfer is determined by formula for convective heat transfer, for exam-
ple, in [20].
Theoretical solution for annular mode of phase flow is analogous to those carried out in
different works for condensation inside vertical tube, e.g., in [16]. In this case, in the majority
of works beginning with [21 to 23] turbulent flow of condensate film and vapor is considered
and the structure of defining parameters, as well as degree of their effect on heat transfer in all
correlations are very similar (see Table 1).

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15th Workshop on Transport Phenomena in Two-Phase flow, 2011

Table 1. Design correlations for estimation of condensation heat transfer


inside horizontal tubes
## Author Design correlation Condensation conditions Reference
⎛ρ ⎞ ⎛μ ⎞
0.5 0,1 Complete
Kutateladze,
1.
S.S.
Nu = 0.0398Rel0.8 Prl0.4 ⎜ l ⎟ ⎜ v ⎟ condensing, [21]
⎝ ρv ⎠ ⎝ μ l ⎠ хin = 1, хout = 0
⎡ ⎛ρ ⎞ ⎤
Anan’yev, ⎢ 1 + хin ⎜ l − 1⎟ + ⎥
Ye.P., 1⎢ ⎝ ρv ⎠ ⎥ Re f > 200
2. Boyko, Nu = с Rel0.8 Prl0.43 ⎢ ⎥ [22]
L.D., Kruz- 2⎢ ⎛ ρl ⎞⎥ Re v > 5 ⋅103
hylin, G.N. ⎢ + 1 + хout ⎜ − 1⎟ ⎥
⎢⎣ ⎝ ρv ⎠ ⎥⎦
Nu = 0.023Rel0.8 Prl0.4 ×
3. Shah ⎡ 3.8 ⎛ x ⎞ ⎤
0.76
[23]
× ⎢1 + 0.38 ⎜ ⎟ ⎥
⎣⎢ pred ⎝ 1 − x ⎠ ⎦⎥
0.9
0.1 x + 0.8
⎛ ρl ⎞ ⎛ x ⎞
4. Fujii Nu = 0.0125 ⎜ Rel ⎟ Prl0.63 [24]
⎜ ρ ⎟ ⎜⎝ 1 − x ⎟⎠
⎝ v ⎠

Nu = 0.023Rel0.8 Prl0.4 ×
5. Tang et al. ⎡ ⎛ x ⎞ ⎤
0.836
Frso > 7 [25]
× ⎢1 + 4.863 ⎜ − ln( pred ) ⎟ ⎥
⎣⎢ ⎝ 1 − x ⎠ ⎦⎥

Dobson ⎛ 2.22 ⎞ ρw ≥ 500


6. Nu = 0.023Rel0.8 Prl0.4 ⎜1 + 0.89 ⎟ [26]
et al. X tt ⎠ kg / (m 2 ⋅ s)

с pl ( ρl τ )
0.5
Kosky &
7.
Staub
α= [32]
Tδ+
Kaushik
⎣⎡( Δxd ) l ⎦⎤
0.198
7.
& Azer
Nu Pr1 3 = 2.078Re0.507 e pr−ed0.14 [27]

Cavallini & λ
8. α = l 0.05Prl1 3 Ree0.8q [28]
Zecchin d
⎛J ⎞
α an − st = ( α an , JG = 2.5 − α st ) ⎜ G ⎟ + α st
⎝ 2.5 ⎠
−1
⎡ ⎛1− x ⎞ ⎤
0.268
J G < 2,5
9. Cavallini α st = 0.725 ⎢1 + 0.82 ⎜ ⎟ ⎥ × [20]
⎢⎣ ⎝ x ⎠ ⎥⎦ X tt < 1.6
⎡ λ 3ρ ( ρ − ρv ) ghlv ⎤
0.25
⎛1− θ ⎞
×⎢ l l l ⎥ + αl ⎜ ⎟
⎣ μ l d ΔT ⎦ ⎝ π ⎠
α f θ + ( 2π − θ ) α с
α lp = ,

⎡ ρ ( ρ − ρv ) ghlv λ 3l ⎤
10. Thome α f = 0.728 ⎢ l l ⎥ [5]
⎣ μv dq ⎦
λ
αc = 0.003Rel0.74 Prl0.5 l fi ;
δ

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15th Workshop on Transport Phenomena in Two-Phase flow, 2011

In [31], five correlations from Table 1 (3, 6, and 8 to 10) for condensation of refriger-
ant R290 at р = 2 MPa and din = 11.9 mm, three values of mass velocity (50, 125, and 200
kg/m2/s) and three values of q (2000, 8000, and 19000 W/m2) are compared. Even in such
example, limited by physical and technical parameters, variety in the values of α calculated by
different correlations reaches 60%, as seen in Fig. 3.

1 – Cavallini at al. [20];

2 – Thome at al. [5];

3 – Dobson-Chato [26];

4 – Cavallini and
Zecchin [28];

5 – Shah [23].
Fig. 3. α plotted against х
for condensing R290
at q = 2000 W/m2 and G =
100 kg/(m2·s).

Poor compliance of various correlations from Table 1 with the experimental results
obtained by different authors should be noted. For example, Kaushik and Azer [27] propose
correlation (7) that generalizes their experimental data on R113 to within ±30%. While in the
work by Fujii [24] the data on condensation of R22, R134a, and R123 are compared with de-
sign correlations (3), (7), and (8) and, as is shown, these correlations give heat-transfer coeffi-
cients lower by 100% and more and only own correlation (4) generalizes the experimental
data to within below 20%.
In [3], the experimental data for various refrigerants are compared as a function α = f ( x ) at
the values of G from 74.6 to 644 kg/(m2·s). It is found that both good compliance of all design
correlations with the experimental data and discrepancy of some results up to 100%, despite
each of the authors of the design correlations demonstrates convergence with own experimen-
tal data within 30%. Fig. 4 from [3], where for the same G (600 kg/(m2·s)) the design and ex-
perimental data for refrigerants R32 and R410A are compared, proves that the proposed de-
sign correlations are not of generalizing type. It is seen that the same correlations satisfacto-
rily comply both with experimental data and with each other for R410A and substantially dis-
agree (up to 100%) for R32.
In [4] and [5], a “new” model for calculation of heat transfer is proposed. It is based
on a simplified flow pattern map with two selected zones: the zone, where heat transfer de-
pends on ∆Т (this zone is closer to the stratified mode of phase flow, i.e., J G ≤ J GT ) and the
zone, where heat transfer does not depend on ∆Т ( J G > J GT ). Such approach is not correct at
least because in an annular mode of phase flow, particularly under laminar film flow of con-
densate, heat transfer decreases with growing ∆Т.

160
15th Workshop on Transport Phenomena in Two-Phase flow, 2011

α,

1 – experimental
data;

2 – Dobson-Chato
[26];

3 – Shah [23];

4 – Fujii [24];
а)
α, 5 – Tang et al.
[25];

6 – Сavallini et al.
[20];

7 – Bivens and
Yokoseki;

8 – Tandon et al.

b)
Fig. 4. α plotted against х for condensation of R410A (a) and R32 (b)
at G = 600 kg/(m2·s).

161
15th Workshop on Transport Phenomena in Two-Phase flow, 2011

The experimental data of many authors are compared in [4] with the proposed calcula-
tion model as the plots of Nucalc Nuexp = f ( x ) . Analysis of them shows that deviation of the
experimental data from those designed both for the refrigerants and for water steam can exceed
60%.

1 – experimental data [11];

2 – Сavallini et al. [20];

3 – Shah [23];

4 – Dobson-Chato [26];

5 – Thome et al. [5].

Fig. 4. α plotted against х


for condensation of water
steam in tube with din=13
mm at р = 8.83 MPa, G =
600 kg/(m2·s), qm= 1120
kW.

In works [7] and [8], the attempts to improve convergence of the experimental data with
calculation models [4] and [5] due to refinement of the transition boundaries of the zones with
heat transfer dependent and independent on ∆Т. Partially improved convergence of the calcula-
tions with the experiments on R134a within the range of G from 75 to 300 kg/m2/s and very low
q (1200 to 3600 W/m2) was obtained.
In Fig. 5, the experimental data on water steam obtained in [11] are compared with the
design correlations (3, 6, 9, and 10) from Table 1. It is distinguishing feature of these data that
in [11] all of the data on x, q, ∆T, G, and α are given in tabular form. Since length of the tubes
l = 2.5 to 12 m, then we calculated the data both at х = 0 to 1.0 and at ∆х not exceeding 0.2 to
0.3. As seen from Fig. 5, there is divergence of all correlations except for [23] that is close to
formula by Boyko.

Conclusion

It is established that in all published works only heat-transfer coefficients of condensa-


tion inside smooth horizontal tubes averaged both over tube’s perimeter and its certain length
(0.5 m and above) were measured. It made impossible to gain proper enough insight into the
features of condensation heat transfer, namely into impact of vapor content and velocity, as
well as condensate accumulation on heat transfer.
Presentation of the experimental data in the form of heat-transfer coefficient (Nusselt
number) as a function of only weight vapor content x or mass velocity G is basically incorrect

162
15th Workshop on Transport Phenomena in Two-Phase flow, 2011

from the point of view of heat transfer under flow of condensate film on the greater part of the
surface, because such analysis does not explain impact of either heat flux or temperature drop
∆Т.
It is shown that the existing correlations for calculation of local and mean coefficients
of heat transfer inside smooth tubes do not correspond with the data obtained in the experi-
ments on different fluids. Discrepancy of calculated and experimental data reaches 30 to 70%
and more.

Nomenclature

cp specific heat at constant pressure, J/kg/K


c empirical coefficient (for cupper tubes c = 0,032)
d tube inner diameter, m
Fr Froude number
fi interfacial roughness correction factor
= xG / ⎡⎣ gd ρ v ( ρl − ρ v ) ⎤⎦ , dimensionless vapor velocity
0.5
JG
g acceleration due to gravity, m/s2
G mass velocity, kg/m2/s
⎡ ρ 0.5

Ge ( )
= G ⎢ x ⎛⎜ l ⎞⎟ + 1 − x ⎥ ,adjusted mass velocity, kg/m2/s
ρv ⎠
⎣ ⎝ ⎦
l length of tube working section, m
Nu Nusselt number
Pr Prandtl number
pred reduced pressure (pressure/critical pressure)
q heat flux, W/m2
hlv latent heat, J/kg
Re Reynolds number
Ree = Ge d / μ l , Reynolds number based on adjusted mass velocity
Tδ+ dimensionless parameter evaluated at the vapor-liquid interface
x vapor mass quality
⎡(1 − x ) ⎤
0.1 0.5 0.9
μ ρ
X tt = ⎛⎜ l ⎞⎟ ⎛⎜ v ⎞⎟ ⎢ , Martinelli parameter
⎝ μ v ⎠ ⎝ ρ l ⎠ ⎣ x ⎥⎦
ΔT saturated vapour-wall temperature difference, K
Δx change in vapour quality from inlet to outlet
α heat-transfer coefficient, W/m2/K
λ heat-conductivity coefficient, W/m/K
δ thickness of liquid film, m
θ upper angle of the tube not wetted by stratified liquid, rad
μ dynamic viscosity, kg/m/s
τ shear stress, N/m
ρ density, kg/m3

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15th Workshop on Transport Phenomena in Two-Phase flow, 2011

Subscripts:
eq equivalent
in – tube inlet;
out – tube outlet;
l – liquid phase;
lp local perimeter
v – vapor phase;
f - film;
φ – tube perimeter;
st - stratified;
an - annular;
tr - transient;
с – convective;
m – mean;
calc – calculated;
exp – experimental

Superscripts
− indicates average

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