Condensation Heat-Transfer Performance of Thermally Stable Superhydrophobic Cerium-Oxide Surfaces

Selective Fabrication of Robust and Multifunctional Super Nonwetting Surfaces by Diverse Modifications of Zirconia-Ceria Nanocomposites

The creation of surfaces with various super nonwetting properties is an ongoing challenge. We report diverse modifications of novel synthesized zirconia-ceria nanocomposites by different low surface energy agents to fabricate nanofluids capable of regulating surface wettability of mineral substrates to achieve selective superhydrophobic, superoleophobic-superhydrophilic, and superamphiphobic conditions. Surfaces treated with these nanofluids offer self-cleaning properties and effortless rolling-off behavior with sliding angles ≤7° for several liquids with surface tensions between 26 and 72.1 mN/m. The superamphiphobic nanofluid coating imparts nonstick properties to a solid surface whereby liquid drops can be effortlessly displaced on the coating with a near-zero tilt and conveniently lifted off using a needle tip, leaving no trace. Further, the superamphiphobic surface demonstrates good oil repellency toward ultralow surface tension liquids such as n-hexane and n-heptane. The superoleophobic-superhydrophilic surface repels oil droplets well regardless of whether it is in the air or underwater conditions. In addition, reaping the benefits of the ZrO₂-CeO₂ nanocomposites' photocatalysis feature, the superoleophobic-superhydrophilic coating exhibits self-cleaning ability by the degradation of color dyes. Modification of the wettability of substrates is carried out by a cost-effective and facile solution-immersion approach, which creates surfaces with hierarchical nano-submicron-scaled structures. The multipurpose coated surfaces have outstanding durability and mechanical stability. They also resist well high-temperature-high-pressure conditions, which will provide various practical applications in different fields, including the condensate banking removal in gas reservoirs or the separation of oil/water mixtures.

Review of droplet dynamics and dropwise condensation enhancement: Theory, experiments and applications

Droplet dynamics and condensation phenomena are widespread in nature and industrial applications, and the fundamentals of various technological applications. Currently, with the rapid development of interfacial materials, microfluidics, micro/nano fabrication technology, as well as the intersection of fluid mechanics, interfacial mechanics, heat and mass transfer, thermodynamics and reaction kinetics and other disciplines, the preparation and design of various novel functional surfaces have contributed to the local modulation of droplets (including nucleation, jumping and directional migration) and the improvement of condensation heat transfer, further deepening the understanding of relevant mechanisms. The wetting and dynamic characteristics of droplets involve complex solid-liquid interfacial interactions, so that the local modulation of microdroplets and the extension of enhanced condensation heat transfer by means of complex micro/nano structures and hydrophilic/hydrophobic properties is one of the current hot topics in heat and mass transfer research. This work presents a detailed review of several scientific issues related to the droplet dynamics and dropwise condensation heat transfer under the influence of multiple factors (including fluid property, surface structure, wettability, temperature external field, etc.). Firstly, the basic theory of droplet wetting on the solid wall is introduced, and the mechanism of solid-liquid interfacial interaction involving droplet jumping and directional migration on the functional surfaces under the various influencing factors is discussed. Optimizing the surface structure for the local modulation of droplets is of guidance for condensation heat transfer. Secondly, we summarize the existing theoretical models of dropwise condensation applicable to various functional surfaces and briefly outline the current numerical models for simulating dropwise condensation at different scales, as well as the fabricating techniques of coatings and functional surfaces for enhancing heat transfer. Finally, the relevant problems and challenges are summarized and future research is discussed.

Robust Micro-Nanostructured Superhydrophobic Surfaces for Long-Term Dropwise Condensation

Design of hierarchical micromorphology represents an important strategy for developing functional surfaces but has yet to be achieved for promising long-term dropwise condensation. Herein, micropapillaes overlaid with nanograss were created to enhance dropwise condensation. By analyzing the nucleation and evolution of the condensate droplets, we elucidated that these hierarchical micro-nanostructures topologized tapered gaps, which produced upward pressure, to achieve spontaneous dislodging of condensate microdroplet out of gaps, and then to trigger microdroplet navigation before finally departing from the surface by coalescence-induced jumping. The high mobility of condensate delayed flooding and contributed to a very high heat transfer coefficient of 218 kW·m^-2·K^-1. Moreover, these micropapillaes served as forts that protected the nanograss from being destroyed, resulting in improved mechanical and chemical robustness. Our work proposed new examples of topology creation for long-term dropwise condensation heat transfer and shed light on application integration of such promising functional surfaces.

High-Temperature Carbonized Ceria Thermophotovoltaic Emitter beyond Tungsten

Thermophotovoltaics (TPVs) require emitters with a regulated radiation spectrum tailored to the spectral response of integrated photovoltaic cells. Such spectrally engineered emitters developed thus far are structurally too complicated to be scalable, are thermally unstable, or lack reliability in terms of temperature cycling. Herein, we report wafer-scale, thermal-stress-free, and wavelength-selective emitters that operate for high-temperature TPVs equipped with GaSb photovoltaic cells. One inch crystalline ceria wafers were prepared by sequentially pressing and annealing the pellets of ceria nanoparticles. The direct pyrolysis of citric acid mixed with ceria nanoparticles created agglomerated, pyrolytic carbon and ceria microscale dots, thus forming a carbonized film strongly adhering to a wafer surface. Depending on the thickness of the carbonized film that was readily tuned based on the amount of citric acid used in the reaction, the carbonized ceria emitter behaved as a tungsten-like emitter, a graphite-like emitter, or their hybrid in terms of the absorptivity spectrum. A properly synthesized carbonized ceria emitter produced a power density of 0.63 W/cm² from the TPV system working at 900 °C, providing 13 and 9% enhancements compared to tungsten and graphite emitters, respectively. Furthermore, only the carbonized ceria emitter preserved its pristine absorptivity spectrum after a 48 h heating test at 1000 °C. The scalable and facile fabrication of thermostable emitters with a structured spectrum will prompt the emergence of thermal emission-harnessed energy devices.

Dropwise condensation: From fundamentals of wetting, nucleation, and droplet mobility to performance improvement by advanced functional surfaces

As a ubiquitous vapor-liquid phase-change process, dropwise condensation has attracted tremendous research attention owing to its remarkable efficiency of energy transfer and transformative industrial potential. In recent years, advanced functional surfaces, profiting from great progress in modifying micro/nanoscale features and surface chemistry on surfaces, have led to exciting advances in both heat transfer enhancement and fundamental understanding of dropwise condensation. In this review, we discuss the development of some key components for achieving performance improvement of dropwise condensation, including surface wettability, nucleation, droplet mobility, and growth, and discuss how they can be elaborately controlled as desired using surface design. We also present an overview of dropwise condensation heat transfer enhancement on advanced functional surfaces along with the underlying mechanisms, such as jumping condensation on nanostructured superhydrophobic surfaces, and new condensation characteristics (e.g., Laplace pressure-driven droplet motion, hierarchical condensation, and sucking flow condensation) on hierarchically structured surfaces. Finally, the durability, cost, and scalability of specific functional surfaces are focused on for future industrial applications. The existing challenges, alternative strategies, as well as future perspectives, are essential in the fundamental and applied aspects for the practical implementation of dropwise condensation.

Investigation of Dropwise Condensation on a Super-Aligned Carbon Nanotube Mesh-Coated Surface

Enhanced vapor condensation is a critical issue for improving the efficiency of energy conversion, thermal management, water recovery, and treatment. Low-energy surfaces incorporating micro/nanoscale roughness have been reported to significantly promote vapor condensation. In this research, the mesh structures of super-aligned carbon nanotube (SACNT) films were prepared by crossing monolayer SACNT films on a copper substrate. Then, the sustaining dropwise condensation was achieved on the SACNT mesh-coated surface. The SACNT mesh-coated surface could obviously enhance the coalescence and sweeping departure of the condensing droplets. Additionally, the measured overall heat transfer coefficient (HTC) of the SACNT mesh-coated surface demonstrated a 36% enhancement compared to that on the bare copper surface. The parallel stacking of SACNT films with different groove structures was also studied, and a 15% enhancement in the HTC was shown as compared with the bare copper surface. Furthermore, we developed a morphology-based model to theoretically analyze the condensation-enhancement mechanism on a SACNT mesh-coated surface. The SACNT surfaces also have advantages of low cost, durability, flexibility, and extensibility. Our findings revealed that the SACNT films could be readily used as vapor condensation-strengthening surfaces, further extending their potential applications to industrial equipment.

Density Maximization of One-Step Electrodeposited Copper Nanocones and Dropwise Condensation Heat-Transfer Performance Evaluation

Currently, it is still a great challenge to obtain copper-based high-efficient dropwise condensation heat transfer (CHT) interfaces via template-free electrodepositing technologies. Here, we report that the density of template-free electrodeposited copper nanocones can maximally reach 1.5 × 10⁶/mm² by the synergistic control of substrate surface roughness, poly(ethylene glycol) (PEG) molecular weight, and PEG concentration. After thiol modification, the densely packed copper nanocone samples can present low-adhesive superhydrophobicity and condensate microdrop self-jumping function at ambient environment. Condensation heat and mass transfer characterizations show that the CHT coefficient of copper surfaces can maximally enhance 98% for 20 °C vapor and 51% for 40 °C vapor by in situ growth of superhydrophobic densely packed copper nanocones. Although the dropwise condensation mode can change from the jumping mode to the mixed jumping and sweeping mode and the shedding-off mode along with the increase of surface subcooling and vapor temperature, the CHT performance of the nanosample is still superior to that of the contrast flat hydrophobic surface during the whole testing range of surface subcooling. As vapor temperature increases to 80 °C, the CHT performance of the nanosample is inferior to that of the contrast sample. The CHT enhancement under low-temperature vapor should be ascribed to the enhancement of small-drop mass transfer ability caused by low-adhesive superhydrophobicity nature of nanosample surfaces. Their performance degradation mainly results from increased drop-drop drag force along with the increase of surface subcooling and vapor temperature. In sharp contrast, the CHT deterioration under high-temperature vapor should be ascribed to larger drop-surface adhesion and drop-drop drag force. The former is caused by vapor penetration, whereas the latter is caused by the dramatically increased nucleation density and growth rate of condensates. These findings would help design and develop copper-based high-efficiency condensation heat transfer interfaces.

Brushed lubricant-impregnated surfaces (BLIS) for long-lasting high condensation heat transfer

Recently, lubricant-impregnated surfaces (LIS) have emerged as a promising condenser surface by facilitating the removal of condensates from the surface. However, LIS has the critical limitation in that lubricant oil is depleted along with the removal of condensates. Such oil depletion is significantly aggravated under high condensation heat transfer. Here we propose a brushed LIS (BLIS) that can allow the application of LIS under high condensation heat transfer indefinitely by overcoming the previous oil depletion limit. In BLIS, a brush replenishes the depleted oil via physical contact with the rotational tube, while oil is continuously supplied to the brush by capillarity. In addition, BLIS helps enhance heat transfer performance with additional route to droplet removal by brush sweeping. By applying BLIS, we maintain the stable dropwise condensation mode for > 48 hours under high supersaturation levels along with up to 61% heat transfer enhancement compared to hydrophobic surfaces.

Passive Anti-Flooding Superhydrophobic Surfaces

Superhydrophobic (SHPo) surfaces can provide high condensation heat transfer due to facilitated droplet removal. However, such high performance has been limited to low supersaturation conditions due to surface flooding. Here, we quantify flooding resistance defined as the rate of increase in the fraction of water-filled cavities with respect to the supersaturation level. Based on the quantitative understanding of surface flooding, we suggest effective anti-flooding strategies through tailoring the nanoscale coating heterogeneity and structure length scale. Experimental verification is conducted using CuO nanostructures having different length scales combined with hydrophobic coatings with different nanoscale heterogeneities. The proposed anti-flooding SHPo can provide a ∼130% enhanced average heat transfer coefficient with ∼14% larger supersaturation range for droplet jumping compared to a previous CuO SHPo. The proposed anti-flooding parameter and the scalable SHPo will help develop high-performance condensers for real-world applications operating in a wide range of supersaturation levels.

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.