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To cite this article: Julio C. Sacramento-Rivero & Peter J. Heggs (2009) The Evaluation of a Vent Condenser by the Film and
Equilibrium Methods for Steam/Air Mixtures, Heat Transfer Engineering, 30:7, 590-597, DOI: 10.1080/01457630802595066
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Heat Transfer Engineering, 30(7):590–597, 2009
Copyright
C Taylor and Francis Group, LLC
ISSN: 0145-7632 print / 1521-0537 online
DOI: 10.1080/01457630802595066
The current design and performance evaluation methods for vent and reflux condensers include minimum safety factors of
30% or more. These oversized condensers incur high capital and operational costs. Experimental data are fundamental in
order to evaluate these design methodologies. This paper presents a new set of experiments performed in a steam/air vent
condenser at subatmospheric pressures. The experimental apparatus consists of a vertical, double-pipe condenser with a
length of 3 m and inner diameter of 0.028 m. The produced experimental data allow the evaluation of the local heat transfer
coefficients and the heat-flux profile on the coolant side. After comparing the predictions of the two main methods for the
design of vent and reflux condensers, that is, the film method and the equilibrium method as modified by Webb et al. (1996),
it becomes apparent that the film method is always better and should be always preferred when diffusive data are available.
The equilibrium method error in predicting the heat transfer area is shown to be a function of the Lewis number. Further
valuable observations are noted regarding the calculation procedures of the two mentioned methods and the risks of using
the equilibrium method.
this paper to work, the vapor velocity must always be less than where the first term is Fick’s law for molar diffusive flux of com-
the flooding velocity. The estimation of the flooding velocity ponent 1 in the y direction with C being the concentration and
is subject to yet greater uncertainties than the design methods D12 the binary diffusivity, and the second term is the convective
themselves and is therefore subject of major interest. The role molar flux where ỹ1 is the molar fraction. The integration across
of the flooding phenomena in the design of vent condensers will the mass transfer film for a binary mixture yields:
be addressed in a future paper. φ
ṅ1 = β12 (ỹg − ỹδ ) + ỹg ṅ (2)
eφ − 1
is measured by a differential pressure cell with an uncertainty of cooling curves were compared. As expected, the differential
± 0.26 inches H2 O (0.0006 bar). However, the variations in the curve consistently predicted larger HTAs than the integral curve,
pressure drop are similar to the accuracy of the pressure trans- but for reasons of space these results are not included here.
ducers because of the variations in the outlet pressure, which The film method requires a stepwise solution of the following
are in turn fixed by the vacuum pump. The flows of condensate set of design differential equations:
from both condensers and the flow of the makeup stream are
measured by direct collection of the condensate for a known (continuity in gas and liquid phases respectively)
volume and time. The coolant flow on the test condenser and
the flow of the dry-air feed into the boiling tank are measured d Ṅg d Ṅl
by rotameters, with an average accuracy of 2.2% and 2.7%, re- × = −ṅ and = −ṅ (10)
dA dA
spectively. The uncertainty on the calculated composition of the
steam/air mixture entering the test condenser is around ± 6%. (energy balance for counter-current coolant)
The energy balances for each experimental run have been
validated by the comparison of the heat load on the boiler and dTc Tδ − Tc
the total condensation duty (see Figure 4). The working con- × = −Ucδ (11)
dA (Ṁcp )c
densation length is inferred from the temperature profiles; i.e.,
the temperature profiles on the wall and on the coolant must (energy balance for vapor mixture cooling)
present a clear increasing trend from the top of the condensing
surface. The maximum propagated uncertainty associated with dTg Tg − Tδ
the energy balances was in the order of ±9% on the annulus × = −αg ξT (12)
dA (Ṅ c̃p )g
side. The agreement of the experiments with the energy balance
was better than 10% for 87% of the experimental runs and better With Eq. (12), the gas/vapor temperature is allowed to depart
than 15% for 96% of the experiments, as illustrated in Figure 4. from saturation conditions. For more details about the ratio-
It was considered that the process had reached a steady state nale of the standard design equations just shown, the reader is
when the temperature profiles on the coolant and process side of referred to HEDH [9]. The preceding equations were solved
the condenser and also the temperature on the boiler presented with the Euler forward-difference method as follows: The outlet
random variations no larger than ± 0.15◦ C. temperature of the coolant is assumed in order to have an initial
value problem and convergence is tested against the known
Figure 5 Temperature profiles and process conditions for experimental runs (a) using low air concentration and (b) using high air concentration.
Downloaded by [University of Texas Libraries] at 11:08 05 May 2015
coolant inlet temperature. Also, the following boundary condi- fraction (ysteam = 0.78), respectively. The operation conditions
tions were considered: are also included in the figures. The HTA is given by the length
of the temperature profiles, and it can be observed in both fig-
Ṅl A=0 = 0 and Ṅl A=AT = Ṅlout ures that the Silver method overestimates it and the film method
slightly underestimates it. Let us examine Figure 5a first. At
Tg A=AT = Tgin = T sat ygin , P in low vapor flows of steam, as in these experiments, the mixture
is expected to remain close to saturation. The film method pre-
Tc |A=0 = Tcin (13) dicts vapor temperatures close to saturation and thus the good
agreement with the Silver method predictions. Also, the wall
ESDU [3] presents a comprehensive comparison of corre- temperature remains close to the vapor temperature and is al-
lations and experimental data for the calculation of the HTC most constant throughout the condensing path. Consequently,
for the gas phase and the condensate film for reflux and vent the condensing temperature difference tends to decrease rapidly
condensation. We followed their recommendations and used the as the coolant flows downward.
Petukov equation and the Nusselt model to calculate the HTC on On the other hand, in Figure 5b, all three temperature profiles
the gas side and the condensate film, respectively. The coolant follow a more parallel path and the change in the temperature
HTC was calculated using the correlation by Dirker and Meyer difference will highly depend on the relative flows of both the
[10] for annular flow. coolant and the gaseous phases. Also, the predictions of the
vapor temperature by the two methods do not match as well as
for purer air due to the departure from equilibrium; i.e., the air
tends to gather close to the condensing interface and will remain
DISCUSSION OF RESULTS slightly cooler than the bulk steam/air mixture, which will be
saturated. This layer of colder air also acts as an additional mass
The experimental conditions used for this analysis are within transfer resistance, reducing the condensation rate compared to
the ranges listed in Table 1. ESDU [3] recommend splitting pure-steam condensation. This is explained as a required steam
the cooling curve into five intervals when using the equilibrium
method. This assumes that the cooling curve is linear within
each interval. When programming the method it is usual to split
the cooling curve in intervals of equal size. This approach re-
quires splitting the curve in more intervals in order to avoid
underprediction of the HTA caused by nonlinearity of the cool-
ing curve, especially toward the top of the condenser. Table 2 is
a summary of the average deviations from the convergent HTA,
that is, the value of area calculated by splitting the cooling curve
in an infinite number of intervals. For small air fractions, the rec-
ommendation by ESDU is safe, but more and more intervals are
required as the air fraction of the inlet vapor increases.
Figure 5a and Figure 5b are plots of the experimental and sim-
ulated temperature profiles for representative runs condensing
virtually pure steam (ysteam = 0.98) and steam with a higher air Figure 6 Predicted condensation heat loads.
Greek Symbols [2] Girard, R., and Chang, J. S., Reflux Condensation Phenomena in
Single Vertical Tubes, International Journal of Heat Mass Trans-
α heat transfer coefficient, kW/m2 K fer, vol. 35, pp. 2203–2218, 1992.
β12 binary mass transfer coefficient, kmol/m2 s [3] ESDU Data Item 89038, Reflux Condensation in Vertical Tubes,
Engineering Sciences Data Unit, 1998. Available online at: http://
δ thickness of boundary layer
www.esdu.com/egi-bin/ps.pl?sess=unlicensed 1081218204908jlf
ε ratio of convective to conductive heat transfer
&t=di&p=89038
φ ratio of condensing flux to mass transfer coefficient [4] Webb, D. R., Fahrner, M., and Schwaab, R., The Relationship
λ thermal conductivity, kW/m K Between the Colburn and Silver Methods of Condenser Design,
ξT Ackermann factor International Journal of Heat and Mass Transfer, vol. 39, pp.
ξM rate factor 3147–3156, 1996.
[5] Al-Shammari, S. B., Liquid Mixing in Reflux Condensation,
Ph.D. thesis, UMIST, Manchester, UK, 2001.
Subscripts [6] Colburn, A. P., and Drew, T. B., The Condensation of Mixed
Vapours, Transactions of the AIChE, vol. 33, pp. 197–215,
c coolant 1937.
conv convection [7] Silver, L., Gas Cooling With Aqueous Condensation, Transac-
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e equilibrium method tions of the Institute of Chemical Engineers, vol. 25, pp. 30–42,
in inner 1947.
[8] Bell, K. J., and Ghaly, M. A., An Approximate Generalized Design
f film method
Method for Multicomponent Partial Condensers, AIChE Sympo-
g gas phase sium Series, vol. 69, pp. 72–79, 1972.
k arbitrary component [9] Webb, D. R., Condensation of Vapour Mixtures, in Heat Exchang-
M mass transfer film ers Design Handbook, ed. G. Hewitt, Begell House, Reading, CT,
o outer pp. 2.6.3-1–2.6.3-25, 1998.
T thermal film [10] Dirker, J., and Meyer, J. P., Heat Transfer Coefficients in Concen-
w wall tric Annuli, Technical Notes, Transactions of the ASME, Journal
δ condensate-film thickness of Heat Transfer, vol. 124, pp. 1200–1203, 2002.