Is dropwise condensation feasible? A review on surface modifications for continuous dropwise condensation and a profitability analysis

Progress and perspectives of sorption-based atmospheric water harvesting for sustainable water generation: Materials, devices, and systems

Establishing alternative methods for freshwater production is imperative to effectively alleviate global water scarcity, particularly in land-locked arid regions. In this context, extracting water from the ubiquitous atmospheric moisture is an ingenious strategy for decentralized freshwater production. Sorption-based atmospheric water harvesting (SAWH) shows strong potential for supplying liquid water in a portable and sustainable way even in desert environments. Herein, the latest progress in SAWH technology in terms of materials, devices, and systems is reviewed. Recent advances in sorbent materials with improved water uptake capacity and accelerated sorption-desorption kinetics, including physical sorbents, polymeric hydrogels, composite sorbents, and ionic solutions, are discussed. The thermal designs of SAWH devices for improving energy utilization efficiency, heat transfer, and mass transport are evaluated, and the development of representative SAWH prototypes is clarified in a chronological order. Thereafter, state-of-the-art operation patterns of SAWH systems, incorporating intermittent, daytime continuous and 24-hour continuous patterns, are examined. Furthermore, current challenges and future research goals of this cutting-edge field are outlined. This review highlights the irreplaceable role of heat and mass transfer enhancement and facile structural improvement for constructing high-yield water harvesters.

Hierarchical Engineering of Sorption-Based Atmospheric Water Harvesters

Harvesting water from air in sorption-based devices is a promising solution to decentralized water production, aiming for providing potable water anywhere, anytime. This technology involves a series of coupled processes occurring at distinct length scales, ranging from nanometer to meter and even larger, including water sorption/desorption at the nanoscale, condensation at the mesoscale, device development at the macroscale and water scarcity assessment at the global scale. Comprehensive understanding and bespoke designs at every scale are thus needed to improve the water-harvesting performance. For this purpose, a brief introduction of the global water crisis and its key characteristics is provided to clarify the impact potential and design criteria of water harvesters. Next the latest molecular-level optimizations of sorbents for efficient moisture capture and release are discussed. Then, novel microstructuring of surfaces to enhance dropwise condensation, which is favorable for atmospheric water generation, is shown. After that, system-level optimizations of sorbent-assisted water harvesters to achieve high-yield, energy-efficient, and low-cost water harvesting are highlighted. Finally, future directions toward practical sorption-based atmospheric water harvesting are outlined.

Experimental Investigation of Dropwise Condensation Shedding by Shearing Airflow in Microgravity Using Different Surface Coatings

The shedding kinematics of water droplets in a condensation environment when exposed to aerodynamic forces in microgravity was studied. Understanding the shedding of droplets from a surface is a critical part of the dropwise condensation process for improving heat transfer. Because gravity as a droplet removal technique is not available in space, the use of airflow to shed droplets is considered for condensing heat exchangers in environmental control and life support systems. Surface coatings affect drop adhesion, and here, four different surfaces (PMMA, PS, PTFE, and SHS) and various droplet sizes (80, 60, and 40 μL) were used to understand the above phenomenon. It was found that the critical velocity to shed a droplet in microgravity was up to 8% lower than that in normal gravity. Also, the effect of the droplet size was investigated for both microgravity and normal gravity; the shedding velocity was lower for microgravity, and it decreased as droplet size increased. Increasing the hydrophobicity of the coating decreased the critical velocity for shedding. Finally, the droplet was found to detach from superhydrophobic surfaces in microgravity. The detachment of droplets from the substrate will hamper the condensation process that can produce a larger fresh area; also, detachment of droplets and entrainment in airflow counter the concept of removing moisture from the air in a dehumidification process.

Assessment of an Exhaust Thermoelectric Generator Incorporating Thermal Control Applied to a Heavy Duty Vehicle

The road transport industry faces the need to develop its fleet for lower energy consumption, pollutants and CO2 emissions. Waste heat recovery systems with Thermoelectric Generators (TEGs) can directly convert the exhaust heat into electric energy, aiding the electrical needs of the vehicle, thus reducing its dependency on fuel energy. The present work assesses the optimisation and evaluation of a temperature-controlled thermoelectric generator (TCTG) concept to be used in a commercial heavy-duty vehicle (HDV). The system consists of a heat exchanger with wavy fins (WFs) embedded in an aluminium matrix along with vapour chambers (VCs), machined directly into the matrix, that grant the thermal control based on the spreading of local excess heat by phase change, as proposed by the authors in previous publications and patents. The TCTG concept behaviour was analysed under realistic driving conditions. An HDV with a 16 L Diesel engine was simulated in AVL Cruise to obtain the exhaust gas temperature and mass flow rate for each point of two cycle runs. A model proposed in previous publications was adapted to the new fin geometry and vapour chamber configuration and used the AVL Cruise data as input. It was possible to predict the thermal and thermoelectric performance of the TCTG along the corresponding driving cycles. The developed system proved to have a good capacity for applications with highly variable thermal loads since it was able to uncouple the maximisation of heat absorption from the regulation of the thermal level at the hot face of the TEG modules, avoiding both thermal dilution and overheating. This was achieved by the controlled phase change temperature of the heat spreader, that would ensure the spreading of the excess heat from overheated to underheated areas of the generator instead of wasting excess heat. A maximum average electrical production of 2.4 kW was predicted, which resulted in fuel savings of about 2% and CO2 emissions reduction of around 37 g/km.

Superhydrophobic Electrodeposited Copper Surface for Robust Condensation Heat Transfer

Superhydrophobic surfaces have great potential for various applications owing to their superior dewetting and mobility of water droplets. However, the physical robustness of nano/microscale rough surface structures supporting superhydrophobicity is critical in real applications. In this study, to create a superhydrophobic surface on copper, we employed copper electrodeposition to create a nano/microscale rough surface structure as an alternative to the nanoneedle CuO structure. The rough electrodeposited copper surface with a thin Teflon coating shows superhydrophobicity. The enhancement of dewetting and mobility of water droplets on copper surfaces by electrodeposition and hydrophobization significantly improved the condensation heat transfer by up to approximately 78% compared to that of copper substrates. Moreover, the nano/microscale rough surface structure of the electrodeposited copper surface exhibits better tolerance to physical rubbing, which destroys the nanoneedle-structured CuO surface. Therefore, the condensation heat transfer of the superhydrophobic electrodeposited copper surface decreased by only less than 10%, while that of the nanoneedle-structured CuO surface decreased by approximately 40%. This suggests that an electrodeposited copper surface can lead to the stable performance of superhydrophobicity for real applications.

Effect of Steam Flow Rate and Storage Period of Superhydrophobic-Coated Surfaces on Condensation Heat Flux and Wettability

The jumping-droplet phenomenon occurring on superhydrophobic (SHPhob) surfaces under special conditions may be beneficial for numerous systems using condensation, due to the reported increased heat transfer coefficients. One technique to create a SHPhob surface is coating, which can be applied to larger areas of existing elements. However, challenges are associated with coating stability and the realization of continuous dropwise condensation. This research examined the condensation of steam at different flow rates (2, 4 and 6 g/min) and its influence on heat flux and water contact angles on the SHPhob spray-coated aluminum samples. Special emphasis on the impact of time was addressed through a series of one and five-hour condensation experiments on the samples with different storage periods (coated either one year ago or shortly before testing). Over the experimental series at a higher steam flow rate (6 g/min), heat flux decreased by 20% through the old-coated samples and water contact angles transferred from the superhydrophobic (147°) to hydrophobic (125°) region. This can be attributed to the joint effects of the partial coating washout and the adsorption of the condensed water within the porous structures of the coating during steam condensation. The new-coated samples could sustain more than fifty hours of condensation, keeping the same heat fluxes and SHPhob characteristics.

Improving heat and mass transfer rates through continuous drop-wise condensation

Drop-wise condensation (DWC) has been the focus of scientific research in vapor condensation technologies since the 20th century. Improvement of condensation rate in DWC is limited by the maximum droplet a condensation surface could sustain and the frequency of droplet shedding. Furthermore, The presence of non-condensable gases (NCG) reduces the condensation rate significantly. Here, we present continuous drop-wise condensation to overcome the need of hydrophobic surfaces while yet maintaining micron-sized droplets. By shifting focus from surface treatment to the force required to sweep off a droplet, we were able to utilize stagnation pressure of jet impingement to tune the shed droplet size. The results show that droplet size being shed can be tuned effectively by tuning the jet parameters. our experimental observations showed that the effect of NCG is greatly alleviated by utilizing this technique. An improvement by multiple folds in mass transfer compactness factor compared to state-of-the-art dehumidification technology was possible.

Formation and Stability of Thin Condensing Films on Structured Amphiphilic Surfaces

We present a microamphiphilic surface to promote the formation of a thin, stable liquid film during condensation. The surface consists of a hydrophilic micropillar array with hydrophobic pillar tips and was made using photolithography, deep reactive ion etching, and liftoff. The hydrophobic tips prevent the liquid film from growing thick, thereby keeping the thermal resistance low without the cyclical growth and shedding process of dropwise condensation. The wetting behavior was modeled analytically, and the parameters required for film formation were determined and verified with ESEM experiments. When a surface filled with condensate and lacked a low-pressure zone for the water to leave, a rupture event occurred, and a large Wenzel droplet emerged to flood the surface irreversibly. A number of strategies were found to combat rupture events. Tilting the surface vertically and dipping in a liquid pool gave the condensate a low-pressure region and prevented rupture. Irreversible flooding can also be avoided by ensuring that the emerged droplet was a nonwetting, highly mobile Cassie droplet. Parameters for Cassie-stable amphiphilic surfaces were determined analytically, but the high aspect ratios required prevented the manufacture of these surfaces for this study. Instead a hierarchical design was presented that demonstrated emerged Cassie droplets without challenging the manufacturing limits of the microfabrication procedure. This design avoided Wenzel droplet flooding without the need for a designated low-pressure zone. Additionally, sites for Cassie emergence could be engineered by removing a single pillar from the array at a designated location.

Foliar water and solute absorption: an update

The absorption of water and solutes by plant leaves has been recognised since more than two centuries. Given the polar nature of water and solutes, the mechanisms of foliar uptake have been proposed to be similar for water and electrolytes, including nutrient solutions. Research efforts since the 19th century focussed on characterising the properties of cuticles and applying foliar sprays to crop plants as a tool for improving crop nutrition. This was accompanied by the development of hundreds of studies aimed at characterising the chemical and structural nature of plant cuticles from different species and the mechanisms of cuticular and, to a lower extent, stomatal penetration of water and solutes. The processes involved are complex and will be affected by multiple environmental, physico-chemical and physiological factors which are only partially clear to date. During the last decades, the body of evidence that water transport across leaf surfaces of native species may contribute to water balances (absorption and loss) at an ecosystem level has grown. Given the potential importance of foliar water absorption for many plant species and ecosystems as shown in recent studies, the aim of this review is to first integrate current knowledge on plant surface composition, structure, wettability and physico-chemical interactions with surface-deposited matter. The different mechanisms of foliar absorption of water and electrolytes and experimental procedures for tracing the uptake process are discussed before posing several outstanding questions which should be tackled in future studies.

Condensing water vapor to droplets generates hydrogen peroxide

It was previously shown [J. K. Lee et al., Proc. Natl. Acad. Sci. U.S.A, 116, 19294-19298 (2019)] that hydrogen peroxide (H2O2) is spontaneously produced in micrometer-sized water droplets (microdroplets), which are generated by atomizing bulk water using nebulization without the application of an external electric field. Here we report that H2O2 is spontaneously produced in water microdroplets formed by dropwise condensation of water vapor on low-temperature substrates. Because peroxide formation is induced by a strong electric field formed at the water-air interface of microdroplets, no catalysts or external electrical bias, as well as precursor chemicals, are necessary. Time-course observations of the H2O2 production in condensate microdroplets showed that H2O2 was generated from microdroplets with sizes typically less than ∼10 µm. The spontaneous production of H2O2 was commonly observed on various different substrates, including silicon, plastic, glass, and metal. Studies with substrates with different surface conditions showed that the nucleation and the growth processes of condensate water microdroplets govern H2O2 generation. We also found that the H2O2 production yield strongly depends on environmental conditions, including relative humidity and substrate temperature. These results show that the production of H2O2 occurs in water microdroplets formed by not only atomizing bulk water but also condensing water vapor, suggesting that spontaneous water oxidation to form H2O2 from water microdroplets is a general phenomenon. These findings provide innovative opportunities for green chemistry at heterogeneous interfaces, self-cleaning of surfaces, and safe and effective disinfection. They also may have important implications for prebiotic chemistry.

Static Wettability of Differently Mechanically Treated and Amphiphobic-Coated Aluminium Surfaces

Wettability, roughness and surface treatment methods are essential for the majority of practical applications, where liquid-solid surface interactions take place. The present study experimentally investigated the influence of different mechanical surface treatment methods on the static wettability of uncoated and amphiphobic-coated aluminium alloy (AlMg₃) samples, specially focusing on the interaction between surface finishing and coating. Five different surfaces were prepared: as-received substrate, polished, sandpapered, fleece-abraded and sandblasted. After characterisation, the samples were spray-coated using an amphiphobic coating. The characterisation of the uncoated and coated samples involved measurements of the roughness parameters and the apparent contact angles of demineralized water and rapeseed oil. The coating was initially characterised regarding its adhesion to the sample and elevated temperature stability. The applied surface treatments resulted in the scattered sample roughness in the range of Sa = 0.3-15.8 µm, water contact angles of θ a p , w = 78°-106° and extremely low oil contact angles. Coating the samples more than doubled the surface roughness to Sa = 13.3-29 µm, whereas the initial surface treatment properties (structure, anisotropy, etc.) were entirely repressed by the coating properties. Coating led the water contact angles to increase to θ a p , w _ c o a t e d = 162°-173° and even more pronounced oil contact angles to increase to θ a p , o _ c o a t e d = 139°-150°, classifying the surfaces as superhydrophobic and oleophobic.

MOF water harvesters

The advancement of additional methods for freshwater generation is imperative to effectively address the global water shortage crisis. In this regard, extraction of the ubiquitous atmospheric moisture is a powerful strategy allowing for decentralized access to potable water. The energy requirements as well as the temporal and spatial restrictions of this approach can be substantially reduced if an appropriate sorbent is integrated in the atmospheric water generator. Recently, metal-organic frameworks (MOFs) have been successfully employed as sorbents to harvest water from air, making atmospheric water generation viable even in desert environments. Herein, the latest progress in the development of MOFs capable of extracting water from air and the design of atmospheric water harvesters deploying such MOFs are reviewed. Furthermore, future directions for this emerging field, encompassing both material and device improvements, are outlined.

Dewetting from Amphiphilic Minichannel Surfaces during Condensation

Condensation heat transfer can be altered significantly by changing the texture and material of a surface to promote droplet removal and therefore lower thermal resistance. These designs are often expensive and fragile, however, and are fabricated using micro- or nanoscale features that are not easily implemented in real-world systems. Here, we present a novel macromachined amphiphilic surface that promotes droplet removal and resists permanent flooding via a spontaneous dewetting transition. While much of the research in condensation involves condensing on surfaces that are fully or mostly hydrophobic, droplets on the surface presented here nucleate and grow inside the structure on a hydrophilic material. The absence of any coating between the liquid and the conductive surface has the benefits of both decreasing thermal resistance and enhancing nucleation density. When the liquid grows to a critical size inside the channel, its elongated shape becomes unstable and spontaneously dewets to form rounded droplets on the hydrophobic fin peaks. The removal of liquid from the channels promotes new growth on the bare hydrophilic material, while the emerged rounded droplets can more easily shed from the hydrophobic fins. The dewetting phenomenon is shown experimentally and characterized analytically such that a desired critical water slug length could be designed by changing geometric parameters of the surface structure. The macroscale machined surface is also more durable than typical nanofabricated surfaces and easier to manufacture, making the surface more applicable to use in real-world systems. Spontaneous condensate dewetting on the amphiphilic structure is expected to enhance the study of inhibiting flooding on condensing surfaces and provide new pathways for droplet shedding techniques without a requirement for nanothin hydrophobic coatings.

Review of Micro–Nanoscale Surface Coatings Application for Sustaining Dropwise Condensation

Condensation occurs in most of the heat transfer processes, ranging from cooling of electronics to heat rejection in power plants. Therefore, any improvement in condensation processes will be reflected in the minimization of global energy consumption, reduction in environmental burdens, and development of sustainable systems. The overall heat transfer coefficient of dropwise condensation (DWC) is higher by several times compared to filmwise condensation (FWC), which is the normal mode in industrial condensers. Thus, it is of utmost importance to obtain sustained DWC for better performance. Stability of DWC depends on surface hydrophobicity, surface free energy, condensate liquid surface tension, contact angle hysteresis, and droplet removal. The required properties for DWC may be achieved by micro–nanoscale surface modification. In this survey, micro–nanoscale coatings such as noble metals, ion implantation, rare earth oxides, lubricant-infused surfaces, polymers, nanostructured surfaces, carbon nanotubes, graphene, and porous coatings have been reviewed and discussed. The surface coating methods, applications, and enhancement potential have been compared with respect to the heat transfer ability, durability, and efficiency. Furthermore, limitations and prevailing challenges for condensation enhancement applications have been consolidated to provide future research guidelines.