ChE 3111 Module 4 Heat Transfer With Phase Change
ChE 3111 Module 4 Heat Transfer With Phase Change
CHE 3111/L
MODULE 4:
CONVECTION
At the end of this module you should be able to:
Solve for heat transfer coefficients and
interpret how these and flow patterns affect
convection heat transfer.
INTRODUCTION
Convection
- Mechanism of heat transfer through a fluid in the presence of bulk fluid motion. It is
classified depending on how the fluid motion is initiated either as:
a. Natural (free) Convection -When the flow of gas or liquid comes from differences
in density and temperature, it is called free convection.
b. Forced Convection -When the flow of gas or liquid is circulated by pumps or fans
it is called forced convection.
- Convection depends on speed. Motion increases heat transfer by convection in all
fluids.
Convection depends on surface area. If the surface contacting the fluid is increased, the
rate of heat transfer also increases. Almost all devices made for convection have fins for this
purpose.
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Convection Equation: q = h A (Ts -T∞)
a. Geometry under consideration. (over a flat plate, over a cylinder, through a tube, through
a channel)
b. Classification of heat transfer process (forced convection, free convection, external flow,
internal flow, entrance region, fully developed region, boiling, condensation, micro-gravity)
c. Type of heat transfer coefficient (local nusselt number or average nusselt number)
Engage
Forced Convection
A forced convection flow field happens when the fluid is forced to flow by pressure
differences, a pump, a fan, and so on.
* Forced convection coefficient can be derived from Nusselt number which is a function of
Reynolds number and Prandtl number. Different correlations are used depending on specific
conditions/ limitations from which these correlations were derived.
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o Turbulent flow – characterized by random
Explore
Reynolds Number
- Reynolds number depends upon different factors such as pipe roughness, vibrations,
upstream fluctuations and disturbances (valves, elbows, etc.)
- It can be calculated as
- The criteria upon which this dimensionless number is analyzed, whether as laminar,
transition or turbulent, depends on the geometry where the fluid flows.
o For flow inside pipes or tubes, the critical Reynolds number
ReD < 2100 laminar
𝐷𝑣𝜌
𝑅𝑒𝐷 = 2300 ≤ ReD ≤ 4000 transitional
𝜇
ReD > 4000 turbulent
Where
D = characteristic length of the geometry
v = mean flow velocity
μ = viscosity
ρ = density
Nusselt Number
- For flow inside or outside tubes : NuD = hD/k
- For flow over flat plates : NuL= hL/k
Prandtl Number
- Prandtl number is based on the boundary layer theory wherein for
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o Pr<<1 heat diffuses very quickly in liquid metals
o Pr>>1 heat diffuses very slowly in oils relative to momentum
𝑚𝑜𝑙𝑒𝑐𝑢𝑙𝑎𝑟 𝑑𝑖𝑓𝑓𝑢𝑠𝑖𝑣𝑖𝑦 𝑜𝑓 𝑚𝑜𝑚𝑒𝑛𝑡𝑢𝑚 𝑣 𝐶𝑝 𝜇
𝑃𝑟 = = =
𝑚𝑜𝑙𝑒𝑐𝑢𝑙𝑎𝑟 𝑑𝑖𝑓𝑓𝑢𝑠𝑖𝑣𝑖𝑡𝑦 𝑜𝑓 ℎ𝑒𝑎𝑡 𝛼 𝑘
- Thermal boundary layer refers to the flow region over the surface in which the
temperature varies in the direction normal to the surface.
Elaborate
When a fluid at one temperature flows along a surface which is at another temperature, a
thermal boundary layer develops. The thermal boundary layer thickness is defined as the
distance required for the temperature T to reach 99% of its free-stream value T∞. And
assuming,
Blasius’ numerical solution with the corresponding values of u and v and that the boundary
layer edge, u/Vx = 0.99, corresponds to η ≈ 5.0;
𝛿 5.0 5.0
≈ ≈
𝑥 √𝑣∞ √𝑅𝑒𝑥
𝑣𝑥
* The transition from laminar to turbulent flow commonly occurs at 300, 000< Re < 600,000
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Explain
● When plate is heated over its entire length of flat plates, xo = 0 (local heat transfer
coefficient)
𝑁𝑢 = 0.332𝑅𝑒1/2 𝑃𝑟1/3
● When average value of Nu over entire length of flat plates, (average heat transfer
coefficient)
𝑁𝑢 = 0.664𝑅𝑒1/2 𝑃𝑟1/3
(for constant heat flux, the coefficient 0.332 becomes 0.453, effecting an increase of
the coefficient over an entire length)
● For laminar flow on an isothermal flat plate with a wide range of Prandtl numbers,
(local heat transfer coefficient)
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Note: average heat transfer coefficient is twice the local heat transfer coefficient
Heat transfer correlations for Turbulent flow
● For flow over flat plate, average heat transfer coefficient. Transition of flow from
laminar to turbulent is not considered.
Sample Problems
1. A crank case of an automobile is approximately 0.6 m long, 0.2 m wide and 0.1 m
deep. Assuming that the surface temperature of the crank case is 350 K, estimate the
rate of heat flow from the crank case to atmospheric air at 276 K at a road speed of
30 m/s. Assume that the vibration of the engine and the chassis induce the transition
from laminar to turbulent over the entire surface. Neglect radiation and assume front
and rear surface have the same average convection coefficient as for the bottom
and sides.
2. Air at a pressure of 101.3 kPa and a temperature of 288.8 K is flowing over a thin,
smooth flat plate at 3.05 m/s. The plate length in the direction of flow is 0.305 m and
is at 333.2 K. Calculate the heat-transfer coefficient assuming laminar flow.
3. Cold air at -28.9 °C and 1 atm is recirculated at a velocity of 0.61m/s over the exposed
top flat surface of a piece of frozen meat. The sides and bottom of this rectangular
slab of meat are insulated and the top surface is 254 mm by 254 mm square. If the
surface of the meat is at -6.7 °C, predict the average heat transfer coefficient to the
surface.
4. Castor oil at 38 OC flows over a wide, 6 m long, heated plate at 0.06 m/s. For a surface
temperature of 93OC, determine a) the hydrodynamic boundary layer thickness at
the end of the plate b) the local heat transfer coefficient h, at the end of the plate
c) the total heat rate from the surface per unit width. Assume the thermal diffusivity to
be 7.22 x 10-8 m2/s, kinematic viscosity to be 6 x 10-5 m2/s and the thermal conductivity
to be 0.213 W/m.K at the film temperature.
5. Atmospheric air at 25 OC flows over both the surface of a flat plate with a velocity of
5 m/s. The flat plate is maintained at a uniform temperature of 75 OC. Determine (a)
the velocity boundary layer thickness and the heat flux at the trailing edge (b)the
total heat transfer from the plate to air
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6. Determine the heat transfer coefficient for the water in a tube of 16 mm in diameter
at a velocity of 3 m/s. The temperature of the tube is 24 °C, and the water enters and
leaves at 80 °C and 36 °C respectively.
7. For heating water from 20°C to 60°C, an electrically heated tube in a constant heat
flux of 10kW/m 2 is proposed. The mass flow rate is to be such that ReD= 2000, the tube
inside diameter is 25mm. The flow is fully developed. Determine the length of the tube.
8. Water at 30°C with a mass flow rate of 2kg/s enters a 2.3 mm ID tube where wall is
maintained at a uniform temperature of 90°C, calculate the length of the tube
required to heat water to 70°C.
9. In a heat exchanger, water flows through a long copper tube (ID=2.2cm) with an
average velocity of 2.13 m/s. The water is heated by steam condensing at 150°C on
the outside of the tube. Water enters at 15°C and leaves at 60°C. What is the heat
transfer coefficient for the water?
Elaborate
Formative Assessment
Answer the following questions. Your answers should be in essay format.
1. Differentiate Biot number from Nusselt number.
2. Explain the concept of fully developed flow.
Evaluate
Evaluative Assessment
1. Air at 25 °C flows past a flat plate at 2.5 m/s. The plate measures 600 mm x 300 mm
and is maintained at a uniform temperature at 95 °C. Calculate the heat loss from the
plate, if the air flows parallel to the 600 mm side. How would this heat loss be affected
if the flow of air is made parallel to the 300 mm side? Assume forced convection.
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Unit 2: Natural Convection
Engage
NATURAL CONVECTION
A free convection/ natural convection flow field is a self-sustained flow driven by the
presence of a temperature gradient. As a result of the temperature difference, the density
field is not uniform. Buoyancy will induce a flow current/ natural circulation due to the
gravitational field and the variation in the density field. In general, a free convection heat
transfer is usually much smaller compared to a forced convection heat transfer.
Free convection refers to fluid motion induced by buoyancy forces. This buoyancy forces
may arise in a fluid for which there are density gradients and a body force that is proportional
to density. Wherein, in heat transfer, density gradients are due to temperature gradients and
the body force is gravitational.
Explore
* Natural convection coefficient is derived from Nusselt number which is a function of
Rayleigh number and Prandtl number.
Rayleigh number
𝑅𝑎𝑥 = 𝐺𝑟𝑥 𝑃𝑟
Grashof number
𝐵𝑢𝑜𝑦𝑎𝑛𝑐𝑦 𝐹𝑜𝑟𝑐𝑒
𝐺𝑟𝑥 =
𝑉𝑖𝑠𝑐𝑜𝑢𝑠 𝐹𝑜𝑟𝑐𝑒
𝑔𝛽 (𝑇𝑠 − 𝑇∞ )𝑥 3
𝐺𝑟𝑥 =
𝑣2
Where x= characteristic dimension of surface; (for vertical flat plates x= length of
plate; for horizontal cylinders x= diameter of tube; horizontal flat surface x= area of
surface/ perimeter)
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𝜌1 – 𝜌2
For non-ideal gases: 𝛽= 𝜌∞ (𝑇𝑠 −𝑇∞ )
1
For perfect gases: 𝛽= 𝑇,𝐾
, where T is the film temperature
MIXED CONVECTION
- A condition for which forced and free convection effects are comparable.
- A number of practical situations involve convection heat transfer that is neither
“forced” nor “free” in nature. The circumstances arise when a fluid is forced over a
heated surface at a rather low velocity. Coupled with the forced-flow velocity is a
convective velocity that is generated by the buoyancy forces resulting from a
reduction in fluid density near the heated surface.
- Aiding flow means that the forced- and free-convection currents are in the same
direction, while opposing flow means that they are in the opposite direction.
- The general notion that is applied in combined-convection analysis is that the
predominance of a heat-transfer mode is governed by the fluid velocity associated
with that mode. An order-of-magnitude analysis of the free-convection boundary-
layer equations will indicate a general criterion for determining whether free-
convection effects dominate. The criterion is that when Gr/Re2 >10 free convection is
of primary importance.
Explain
SAMPLE PROBLEMS
1. Determine the rate of heat loss from a heated pipe as a result of natural convection.
Tw=100°C, Tair= 0°C, OD pipe= 0.1m
3. A circular disk heater 0.2m in diameter is exposed to ambient air at 25°C. One surface
of the disc is insulated and the other surface at 130°C. Calculate the amount of heat
transferred from disc to air when it is a) horizontal with hot surface facing upward; b)
horizontal with hot surface facing downward c) vertical.
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4. The size of the CPU of a personal computer is 40cm wide, 50 cm deep and 10 cm
high. Its top surface is dissipating 25 W to the surrounding air at 20°C. Calculate the
temperature of the top surface.
5. Calculate the convection heat loss from the top and bottom of a flat 1 m square
horizontal restaurant grill heated to 227°C in ambient air at 27°C.
6. A heated vertical wall 1 ft high of an oven for baking food with the surface at 450 OF
is in contact with air at 100OF. Calculate the heat transfer coefficient and the heat
transfer/ft width of wall. Note that heat transfer for radiation will not be considered.
7. Atmospheric air is between two parallel, vertical plates separated by 2.5 cm. The
plates, which are 1.8 m high and 1.2 m wide, are at temperature of 50 OC and 4OC,
respectively. Estimate the heat transfer across the air space.
8. Two vertical square metal plates with sides equal to 0.4 m are separated by a gap of
12 mm and this enclosed space is filled with water. The average surface temperature
of one plate is 65.6OC and the other plate is 37.8OC. Calculate the heat transfer rate
through the gap.
9. Air at 1 atm absolute pressure and 366.5 K is enclosed between two vertical plates
where L = 0.6 m and thickness = 30mm. The plates are 0.4 m wide. The plate
temperature is 394.3 K. calculate the heat transfer rate across the air gap.
Elaborate
FORMATIVE ASSESSMENT
1. Answer item 5 from the sample problems for Natural Convection.
Evaluate
EVALUATIVE ASSESSMENT
1. Answer item 6 from the sample problems for Natural Convection.
2. Answer item 9 from the sample problems for Natural Convection.
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Unit 3: Heat Transfer with Phase Change
Engage
HEAT TRANSFER WITH PHASE CHANGE
Energy transfer processes associated with phase change may achieve relatively high heat
transfer rate although the accompanying temperature differences are quite small. These
convective heat-transfer processes are difficult to describe because of additional
considerations of latent heat of vaporization, surface characteristics and other properties of
two-phase systems.
Example of phase change includes the melting of ice and boiling of water.
From the Heating Curve of Water shown in the figure above, the following are observed:
1. Potential energy of Solid < Liquid < Gas
2. During phase change, potential energy, not kinetic energy (temperature) changes.
3. Heating or cooling a changing phase does not change its temperature.
Explore
In this module, we are going to focus on two types of phase change, namely condensation
and boiling.
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CONDENSATION
Condensation occurs when a vapor contacts a surface that is at a temperature below the
saturation temperature of the vapor. When the liquid condensate forms on the surface, it will
flow under the influence of gravity. The flow maybe laminar or turbulent, depending on the
fluid, rate of condensation, tube size and other factors. The film tends to thicken as it flows to
the bottom of the tube, and the weight of the fluid may cause ripples to form. These will
cause deviations from pure laminar flow.
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occurs if the surface is coated with a substance that inhibits wetting
the average heat transfer coefficient for dropwise condensation may be 5 to 8 times
that for film-type condensation
BOILING
Boling or Vaporization of liquids may result from various mechanisms of heat transfer, singly
or combinations thereof. For example, vaporization may occur as a result of heat absorbed,
by radiation and convection, at the surface of a pool of liquid; or as a result of heat absorbed
by natural convection from a hot wall beneath the disengaging surface, in which case the
vaporization takes place when the superheated liquid reaches the pool surface.
Vaporization also occurs from falling films (the reverse of condensation) or from the flashing
of liquids superheated by forced convection under pressure.
The excess temperature is the surface temperature above the boiling point of the liquid.
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Physical Mechanisms of Boling:
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Explain
CONDENSATION
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Vertical tier of N horizontal tubes
For a vertical tier of N horizontal tubes placed one below the other,
the average convective coefficient over the N tubes is given by,
L ( L − v ) gh fg D 3
1/ 4
hD
N Nu = = 0.725
kL N L k L T
This equation works al so for N = 1.
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BOILING
h = 0.168 ( T ) h = 5.56 ( T )
3 3
q / A 5000 q / A 16
q / A 75, 000 q / A 240
For vertical surfaces:
2 o 2
English ( h : BTU/hr-ft - F) Metric (h : kW/m )
h = 87 ( T ) h = 537 ( T )
1/ 7 1/7
q / A 1000 q/ A3
h = 0.240 ( T ) h = 7.95 ( T )
3 3
q / A 1000 q/ A3
q / A 20, 000 q / A 63
h = 2.55 ( T ) e P / 1551
3
Metric: T : K; h : W/m 2 K P : kPa
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Sample Problems:
1. Steam saturated at 68.9 kPa is condensing on a vertical tube 0.305 m long having an
OD of 0.0254 m and a surface temperature of 86.11OC. Calculate the average heat
transfer coefficient using English and SI units.
2. Saturated steam condenses on the outside of a 5 cm diameter vertical tube, 50 cm
high. If the saturation temperature of the steam is 302 K, and cooling water maintains
the wall temperature at 299 K, determine:
a. the average heat transfer coefficient,
b. the total condensation rate, and
c. the film thickness at the bottom of the tube.
3. Air free saturated steam at 90 OC condenses on the outer surfaces of 2.5-cm OD 6 m
long vertical tube, where outer surface temperature is maintained at a uniform
temperature of 60OC. Calculate the total rate of condensation of steam at the total
surface.
4. Water is being boiled at 1 atm abs pressure in a jacketed kettle with steam
condensing in the jacket at 115.6OC. The inside diameter of the kettle is 0.656 m and
the height is 0.984 m. the bottom is slightly curved but it will be assumed to be flat.
Both the bottom and the sides up to the height of 0.656 m are jacketed. The kettle
surface for heat transfer is 3.2 mm stainless steel with a k of 16.27 W/m.K. the
condensing steam coefficient hi inside the jacket has been estimated as 10200
W/m.K. Predict the boiling heat transfer coefficient ho for the bottom surface of the
kettle.
Elaborate
FORMATIVE ASSESSMENT
1. Air free saturated steam at 85OC condenses on the outer surfaces of 225 horizontal
tubes of 1.27 cm OD, arranged in a 15 x 15 array. Tube surfaces are maintained at a
uniform temperature of 75OC. Calculate the condensate rate per one m length of
tube. (Ans. 𝑚̇=0.2793 x 10 -3 kg/s)
2. Calculate the heat transfer coefficient and the mass flow rate during stable film
boiling of water from a 0.9 cm diameter horizontal carbon tube. The water is saturated
𝑘𝑔
and at 100OC. The tube surface is at 1000OC. (Ans. A= 0.0283 m2, 𝑚̇ = 1.6414 𝑥10−3 𝑠
)
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Evaluate
EVALUATIVE ASSESSMENT
References
Geankoplis, Christie J. Transport Process and Unit Operations, 3rd Ed., PTR Prentice Hall, c
1995.
Green, Don W. Perry’s Chemical Engineers’ Handbook , 8th Ed. McGraw Hill Professional,
c2008.
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