Many industrial plants depend on water vapor¹ condensing on metal plates: In power plants, the resulting water is then returned to a boiler² to be vaporized again; in desalination³（脱盐） plants, it yields a supply of clean water. The efficiency of such plants depends crucially on how easily droplets⁴ of water can form on these metal plates, or condensers⁶, and how easily they fall away, leaving room for more droplets to form. The key to improving the efficiency of such plants is to increase the condensers' heat-transfer coefficient -- a measure of how readily heat can be transferred away from those surfaces, explains Nenad Miljkovic, a doctoral student in mechanical engineering at MIT. As part of his thesis research, he and colleagues have done just that: designing, making and testing a coated surface with nanostructured patterns that greatly increase the heat-transfer coefficient.

 

The results of that work have been published in the journal Nano Letters, in a paper co-authored by Miljkovic, mechanical engineering associate professor Evelyn Wang, and five other researchers from the Device Research Lab (DRL) in MIT's mechanical engineering department.

 

On a typical, flat-plate condenser⁷, water vapor condenses to form a liquid film on the surface, drastically reducing the condenser's ability to collect more water until gravity drains the film. "It acts as a barrier to heat transfer," Miljkovic says. He and other researchers have focused on ways of encouraging water to bead⁸ up into droplets that then fall away from the surface, allowing more rapid water removal.

 

"The way to remove the thermal⁹ barrier is to remove [the droplets] as quickly as possible," he says. Many researchers have studied ways of doing this by creating hydrophobic（狂犬病的） surfaces, either through chemical treatment or through surface patterning. But Miljkovic and his colleagues have now taken this a step further by making scalable surfaces with nanoscale features that barely touch the droplets.

 

The result: Droplets don't just fall from the surface, but actually jump away from it, increasing the efficiency of the process. The energy released as tiny droplets merge¹⁰ to form larger ones is enough to propel the droplets upward from the surface, meaning the removal of droplets doesn't depend solely¹¹ on gravity.

 

Other researchers have worked on nanopatterned surfaces to induce such jumping, but these have tended to be complex and expensive to manufacture, usually requiring a clean-room environment. Those approaches also require flat surfaces, not the tubing or other shapes often used in condensers. Finally, prior research has not tested the enhanced heat transfer predicted for these types of surfaces.

 

In a paper published early in 2012, the MIT researchers showed that droplet⁵ shape is important to enhanced heat transfer. "Now, we've gone a step further," Miljkovic says, "developing a surface that favors these kinds of droplets, while being highly scalable and easy to manufacture. Furthermore, we've actually been able to experimentally measure the heat-transfer enhancement."

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