Effect of Non-Condensable Gas On Condensation Heat Transfer

BARC
4th RCM on the IAEA CRP on Natural Circulation Phenomena, Modelling

and Reliability of Passive Safety Systems
that Utilize Natural Circulation
Effect of non-condensable gases on

condensation heat transfer
N.K. Maheshwari, P.K. Vijayan and D. Saha

Reactor Engineering Division,
Bhabha Atomic Research Centre,
Trombay, Mumbai, INDIA - 400 085
Vienna, Austria, September 10-13, 2007
BARC
Effect of Non-condensable gases on condensation

The present talk deals with state of art on the effect of noncondensable gases on condensation heat transfer
The problem is relevant to containment cooling using Passive
Containment Cooling System (PCCS).
Containment of a nuclear reactor is a key component of the
mitigation part of the defence in depth philosophy, since it is the
last barrier designed to prevent large radioactive releases to the
environment.
To provide safety-grade heat sink for preventing the
containments exceeding its design pressure, passive systems
for condensing steam are used in the nuclear reactors.
BARC
The other important system encountering condensation in

presence of noncondensable gas is the power plant condenser.
The presence of noncondensable gas greatly influences the
condensation process warranting in-depth study of the
phenomena.
BARC
Definition
Condensation occurs when the temperature of vapor is reduced
below its saturation temperature.
Presence of even a small amount of Non-condensable gas (e.g.
air, N2, H2, He, etc.) in the condensing vapor leads to a
significant reduction in heat transfer during condensation.
The buildup of non-condensable gases near the condensate
film inhibits the diffusion of vapor from the bulk mixture to the
liquid film.
BARC
Schematic representation of the effect of

non-condensable gas on condensation
BARC
The geometries of interest are tubes, plates, annulus, etc. and the flow
orientation (horizontal, vertical) can be different for various applications.
The condensation heat transfer is affected by parameters such as
Mass fraction of non-condensable gas

System pressure
Gas/vapor mixture Reynolds number
Orientations of surface
Interfacial shear
Prandtl number of condensate
Multi-component non-condensable gases, etc.
BARC
Scenario
During a loss-of-coolant accident (LOCA) or a main-steam-linebreak (MSLB) accident, or any other accident that causes a
coolant release into the containment.
A large amount of steam is released into the containment which
mixes with the noncondensable gases.
There are cooling surfaces provided for condensing the steam
from steam/non-condensable gas mixture.
During condensation process, the steam condenses on the
surfaces, while the non-condensable gases are accumulated
on the film condensate layer creating an additional thermal
resistance resulting in a degradation of the heat transfer to the
wall.
BARC
Scenario
In the design and operation of a steam turbine the exit
temperature of the process fluid is kept as low as possible
so that a maximum change in enthalpy occurs during the
conversion of heat into work. The presence of small
proportion of air in the vapor can reduce heat transfer
performance in a marked manner which increases the
condenser pressure.
BARC
Hardware
PCCS with isolation Condenser
The system is adopted in ESBWR and SBWR

BARC
Hardware
PCCS with steel containment vessel
The Westinghouse AP-600, SPWR, EP-1000, JPSR

and AC-600 are the reactors utilizing this concept.
BARC
Hardware
PCCS with Building Condenser
SWR-1000: Containment Pressure Reduction and Heat Removal following

a LOCA using Steam Condensation on Condenser Tubes.
BARC
Hardware
GD W P
Gravity driven water

pool
Passive
external
condenser
Secondary Containment
Primary Containment
Steamnoncondensable gas
Condensate
Turbin
e
Passive
External
condensed
Condenser
Core
General Arrangement of AHWR with PCCS

FIG 1. SCHEM A TIC OF PA SSIV E CO NTAIN M EN T COOLE R
BARC
Literature review
Stagnant environment
Test
performed
Geometry and
size
Working fluid
Remarks
Othmer
Copper tube
D= 76.2 mm, L=1.22 m
Air/steam
Reduction in heat transfer coefficient (HTC) by 50%

when 0.5% air is present in steam
Uchida
Vertical tube
D=0.2 m, L=0.3 m
Air, Nitrogen and

Argon with Steam
The correlation developed is widely used in nuclear

reactor containment analysis
Al-Diwani and
Rose
Cooled vertical copper

plate, 97 x 97 mm
Air, Argon and Helium

with
Experimental data show good agreement with the

published data
Dehbi et al.
Vertical copper tube

D=38 mm, L=3.5 m
Air/Steam
Air-Helium-Steam
Developed correlations for air/steam and airHelium and steam mixture. Heat transfer coefficient
estinated by heat and mass transfer model agree
well with exptl. data
Liu et al.
Vertical copper tube

D=40 mm, L=2 m
Air, Helium with Steam
Developed a correlation and found that HTC is 2.2

times higher than HTC estimated by Uchida
correlation
BARC
Literature review
Stagnant environment
Test performed
Geometry, orientation and

size
Working fluid
Maheshwari et al.
Horizontal tube
D=21.3 mm, L=0.75 m
Air/Steam
HTC for horizontal tube is

higher than vertical tube
Anderson et al.
Vertical and Horizontal

Condensing plates
Characteristic length, L= 0.91 m
Air/steam and Air-HeliumSteam
Effect of orientation of
condensing surface was
found to be small
Remarks
BARC
Literature review
Flowing vapor-noncondensable gas mixture
Test
performed
Geometry and size
Working
fluid
Remarks
Nitrogen/Steam
Helium/Steam
Facility is called GIRAFFE system. The results for

average HTC were presented in terms of degradation
coefficient (ratio of actual HTC and pure steam HTC by
Nusselt theory)
Nagasaka et al.
Vertical SS tube
(Full scale SBWR PCC
tube)
Masoni et al.
Vertical tube
(Full scale SBWR PCC
tube)
Air/steam
PANTHERS exptl. Facility. The results are given in

terms of condenser efficiency as a function of inlet
pressure and air mass fraction
Ogg
Vertical SS tube
ID=49.0 mm, L=2.44 m
Air/Steam and
Helium/ Steam
A correlation for heat transfer coefficient was

developed based on the experiment in term of
Nusselts pure steam heat transfer coefficient and
degradation factor consisting the two separate factors
which involves mixture Reynolds number and air mass
fraction.
Hassanein et al.
Vertical SS tube
ID=46 mm, L=2.54 m
Air/Steam and
Helium/Steam
The local Nusselt number was correlated as a function

of local mixture Reynolds number, Jakob number and
gas mass fraction and Schmidt number.
Vierow
Vertical coper tube

ID=22.1 mm, L=2.13 m
Air/Steam
The authors found that at an air inlet mass fraction of

14% the heat transfer coefficients were reduced to
one-seventh the values of pure steam. Instabilities
were observed at high air contents. Vierow developed
a correlation for local heat transfer coefficient
BARC
Literature review
Flowing vapor- noncondensable gas mixture
Test
performed
Geometry
and size
Working
fluid
Remarks
Siddique
Vertical tube
ID= 25.27 mm,
L=1.22 m
Air/Steam and
Helium/ Steam
For same mole fraction, compared to helium air has more

inhibiting effect on condensation heat transfer, but for the
same mass ratio, helium is found to be more inhibiting.
They developed correlations.
Araki
Vertical tube
ID=49.5 mm, L=1.21
m
Air/Steam
Correlations for condensation HTC for laminar and

turbulent range are developed in terms of Reynolds
number and air mass fraction
Kuhn
Vertical SS tube
ID=50.8 mm, L=2.4 m
Air/Steam and
Helium/ Steam
The local Nusselt number was correlated as a function of

local mixture Reynolds number, Jakob number and gas
mass fraction and Schmidt number. .
Park et al.
Vertical tube
Air/Steam
Correlation for local HTC in terms of degradation factor is

developed. The range of validity for Jakob number in the
correlation is smaller than that of the correlation
developed by Siddique et al.
Maheshwari et al.
Vertical tube
ID=42.76 mm, L=1.6
m
Air/Steam
Experiments were performed with natural convection of

water outside the tube and with forced flow of water
flowing in a cooling jacket surrounding the tube.
Correlation is developed. A strong dependency of heat
transfer coefficient on Reynolds number of the inlet
mixture was also found
BARC
Heatmass
and mass
transfer
Heat and
transfer
coefficient
The heat transfer through the condensate film
is balanced by the heat transfer through the
gas/vapor interface which is sum of latent heat
and sensible heat. This yields
tot
1
1
h
h
h
f
cond
g
hcond Condensation heat transfer coefficient , hf Film heat transfer coefficient

hg - Convective heat transfer coefficient
Where, hcond is given by eq.,

h
(T - T ) m // H
cond b i
cond fg
A mass balance at the interface is done to yield the following equation

//
Wnc,i
m cond
L
Sh
D Wnc,i Wnc,b
where, L is the characteristic length which is outer diameter

for horizontal tube and length of the tube for vertical tube
BARC
cond
(T - T ) m // H
b i
cond fg
Condensate film heat transfer
Condensate film model

The film heat transfer coefficient on vertical surface is calculated by
Nusselt equation
l l g gHfg k
h f 0.943
L
T
T
l
i
w
3
l
1
4
for Ref < 30
For condensation on horizontal tube the 0.943 is replaced by 0.725 in

Nusselt equation
BARC
Gas/vapor heat transfer- free convection

Heat transfer at gas/vapor boundary layer
In case of stagnant gas environment, the natural convection boundary
layer approach provides the expressions for sensible heat transfer
through the gas/vapor boundary layer formed during condensation of
vapor.
Nu 0.56 Gr Pr
Nu 0.13 Gr Pr
hg can be
expression
0.25
(for Gr 10 9 )
0.33
(for Gr 10 )
obtained
from
(12)
above
By heat and mass transfer analogy

Sh 0.56 GrSc
Sh 0.13 GrSc
0.25
(for Gr 10 9 )
0.33
(for Gr 10 )
9
(13)
The Grashof number is

defined as
g ,b gL3
Gr
( g ,i g ,b )
2
m//cond and hcond can be estimated

from equations (11) and (4)
BARC
Gas/vapor heat transfer- Forced convection
Heat transfer at gas/vapor boundary layer

In case of vapor/gas mixture flowing inside a vertical tube, the forced
convective boundary layer approach provides the expressions for sensible
heat transfer through the gas/vapor boundary layer formed during
condensation of vapor. The following Gnielinski correlation is used
Nu
(f /2)(Re - 1000)Pr
s
1 + 12.7(f /2)1/2 (Pr 2/3 - 1)

s
2300< Re < 5 x 106
By heat and mass transfer analogy
Sh
(f /2)(Re - 1000)Pr
s
1 + 12.7(f /2)1/2 (Sc 2/3 - 1)

s
Re is local mixture Reynolds number in

the bulk fluid, and fs is the friction factor
for smooth tube
When the Reynolds number is less than 2300, a fully developed laminar
flow regime is assumed. A value of 3.66 is assigned for Nu and Sh
BARC
Heat transfer enhancement
Following modifications are carried out to account for the

Film Waviness/ripple effect on condensate film heat transfer
coefficient
Condensate film roughness effect on condensation and convective
heat
transfer
Suction effect
Developing flow effect on heat and mass transfer
BARC
Correlations
Some of the correlations available in literature
Number of correlations are available in the literature. Some of the
correlations developed are given below.
Condensation in stagnant atmosphere

The correlation developed by Uchida
htot (Uchida )
Wnc
380
1 Wnc
0.7
The Tagami correlation
htot
W nc
11.4 284
1 W nc
BARC
Correlations
Dehbi correlation
h tot(Dehbi)
L0.05 3.7 28.7Ptot 2438 458.3Pt logWnc
Tb Tw 0.25
for 0.3 m < L < 3.5 m; 1.5 atm. < Pt < 4.5 atm.;10 oC < (Tb-Tw) < 50 oC
The correlation developed by Liu et al.
0.252
h tot CX s2.344 Ptot
dT 0.307
2.533 x 105 Pa < Ptot < 4.559 x 105 Pa

4 oC < dT < 25 oC; 0.395 < Xs < 0.873
Where, C=55.635 W/m2 Pa0.252 oC1.307
BARC
Correlations
Condensation inside the vertical tube
There are two types of correlations for estimating the heat transfer
coefficient.
The local heat transfer coefficient is expressed in the form of a
degradation factor defined as the ratio of the experimental heat
transfer coefficient (when noncondensable gas is present) and pure
steam heat transfer coefficient.
The degradation factor is a function of local noncondensable gas
mass fraction and mixture Reynolds number (or condensate
Reynolds number).
BARC
Correlations
The local heat transfer coefficient is expressed in the form of

dimensionless numbers and does not require information of
condensation heat transfer coefficient for pure steam.
In these correlations, local Nusselt number is expressed as a
function of mixture Reynolds number, Jacob number,
noncondensable gas mass fraction and condensate Reynolds
number, etc.
BARC
Correlations
The degradation factor is defined as
f
h tot
h film
Vierow correlation based on UCB data

1.1
f 0.0050 Re o.45
film W
a
Park correlation based on KAIST data

f 0.0012 Wa1.4 Ja 0.63 Re 0.24
film
Which is applicable in the following range

1715 < Reg < 21670
0.83 < Prg < 1.04
0.111 < Wa < 0.836
0.01654 < Ja < 0.07351
BARC
Correlations
Correlation based on non-dimensional numbers
Siddique Correlation based on MIT data
Nu(x) 1.137Re 0.404
Wa1.105 Ja 0.741
g
Which applies in the following range of experiments

0.1
< Wa < 0.95 ; 445
< Reg < 22700 ; 0.004 < Ja < 0.07
Maheshwari correlation based on BARC experiments

.15
Wa 0.85 Ja 0.8 Re 0g.5
Nu ( x) 0.15 Re 0film
This equation is valid in the following range

0.1
< Wa < 0.6
8000 < Reg < 22700
0.005 < Ja < 0.07
BARC
Condensation inside a vertical tube

Work done in BARC on condensation inside vertical tube
Experimental studies on condensation in presence of air in vertical tube
Development of a theoretical model to investigate condensation in
presence of noncondensable gas when steam/air mixture is flowing
down inside the tube
Studies on the effects of various parameters on condensation in
presence of noncondensable gas
Comparison of theoretical results with BARC experimental data and
data available in literature
BARC
Condensation in vertical tube

400
1000
260
100
A
100
1600
50
48.3
950
Section -AA
Condensate
line
Test set-up
Geometry and
Dimensions of the
model
Air vent line
BARC
Forced flow condensation
Variation of total heat transfer coefficient

along the length of the tube
BARC
Condensation in stagnant environment

Work done in BARC on condensation in stagnant environment
Experimental studies on condensation in presence of air over

horizontal tube
Development of a theoretical model to investigate condensation in
presence of noncondensable gas when steam/air mixture is nonflowing
Studies on the effects of various parameters on condensation in
presence of noncondensable gas
Comparison of theoretical results with BARC experimental data and
data available in literature
BARC
Experiment set up
Thermocouple
Pressure transmitter
Level transmitter
T
P
LT
Relief
valve and
rupture
dick
Insulated lines
P
condensing Section
21.3 mm OD tube
750
1000
LT
2000
Nozzles for
vertical
installation of
model
Rotameter (0-8 lpm)
Water
Pressure
regulator
Compressed
air
Water inlet
Heater
0-18 kW
To drain
Schematic of the steam condensation experimental set up

BARC
Comparison between
experimental and theoretical results
Variation of heat transfer coefficient with air mass fraction

BARC
Free and forced convective Condensation
Comparison of free and forced convective heat transfer coefficients

BARC
Summary
Work done by various researchers is reviewed
The report deals with the following
- Condensation in stagnant steam/non-condensable environment
- Condensation in a flowing steam/non-condensable mixture
- Geometry considered -tubes with different orientations, plate, etc.
Recent work performed in BARC is also presented

Effect of Non-Condensable Gas On Condensation Heat Transfer

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BARC

4th RCM on the IAEA CRP on Natural Circulation Phenomena, Modelling

Effect of non-condensable gases on

N.K. Maheshwari, P.K. Vijayan and D. Saha

Vienna, Austria, September 10-13, 2007

Effect of Non-condensable gases on condensation

Vienna, Austria, September 10-13, 2007

Effect of Non-condensable gases on condensation

The other important system encountering condensation in

Vienna, Austria, September 10-13, 2007

Effect of Non-condensable gases on condensation

Vienna, Austria, September 10-13, 2007

Effect of Non-condensable gases on condensation

Schematic representation of the effect of

Effect of Non-condensable gases on condensation

Mass fraction of non-condensable gas

Vienna, Austria, September 10-13, 2007

Vienna, Austria, September 10-13, 2007

Vienna, Austria, September 10-13, 2007

The system is adopted in ESBWR and SBWR

The Westinghouse AP-600, SPWR, EP-1000, JPSR

SWR-1000: Containment Pressure Reduction and Heat Removal following

Gravity driven water

General Arrangement of AHWR with PCCS

FIG 1. SCHEM A TIC OF PA SSIV E CO NTAIN M EN T COOLE R

Reduction in heat transfer coefficient (HTC) by 50%

Air, Nitrogen and

The correlation developed is widely used in nuclear

Cooled vertical copper

Air, Argon and Helium

Experimental data show good agreement with the

Vertical copper tube

Vertical copper tube

Air, Helium with Steam

Developed a correlation and found that HTC is 2.2

Vienna, Austria, September 10-13, 2007

Geometry, orientation and

HTC for horizontal tube is

Vertical and Horizontal

Air/steam and Air-HeliumSteam

Vienna, Austria, September 10-13, 2007

Geometry and size

Facility is called GIRAFFE system. The results for

PANTHERS exptl. Facility. The results are given in

A correlation for heat transfer coefficient was

The local Nusselt number was correlated as a function

Vertical coper tube

The authors found that at an air inlet mass fraction of

Vienna, Austria, September 10-13, 2007

For same mole fraction, compared to helium air has more

Correlations for condensation HTC for laminar and

The local Nusselt number was correlated as a function of

Correlation for local HTC in terms of degradation factor is

Experiments were performed with natural convection of

Vienna, Austria, September 10-13, 2007

hcond Condensation heat transfer coefficient , hf Film heat transfer coefficient

Where, hcond is given by eq.,

A mass balance at the interface is done to yield the following equation

where, L is the characteristic length which is outer diameter

Vienna, Austria, September 10-13, 2007

Condensate film heat transfer

Condensate film model

for Ref < 30