BKF2422 HEAT TRANSFER

CHAPTER 3
Part 1
Principles of steady-state heat
transfer in convection

FORCED CONVECTION
 TOPIC OUTCOMES
 Define and differentiate between forced convection and
natural convection
 Solve problems involve with forces convection inside pipe

 Determine the heat transfer coefficient and solve problems

for heat transfer in system with fluid flow across plate, tube
cylinder, sphere and bank of tubes.
 CONTENT
 Forced Convection Heat Transfer Inside Pipe
 For laminar flow inside pipe
 For turbulent flow inside pipe
 For transition flow inside pipe
 Entrance-region effect on heat transfer coefficient
 Liquid-metal heat transfer coefficient
 Log mean Temperature Difference

 Heat Transfer Outside Various Geometries In Forced Convection

 Flow Parallel to Flat Plate

 Flow Past Cylinder With Axis Perpendicular
 Flow Past Single Sphere
 Flow Past Banks of Tubes or Cylinders
 Flow Past in Packed Beds
 CONTENT
 Natural convection
 From planes and cylinders
 In enclosed spaces
 Boiling
 Nucleate boiling
 Film boiling
 Condensation

 Film-condensation coefficient for vertical surfaces

 Film-condensation coefficient for horizontal cylinders
 CONVECTION HEAT TRANSFER

 Convection: Heat transfer using movement of fluids.

 Heat transfer is considered as convection with the presence of
bulk fluid motion. Fluid motion enhances heat transfer where
the higher the fluid velocity, the higher the rate of heat
transfer.
 2 main classification of convective heat transfer;

1. Forced Convection : fluid flow by pressure differences, a pump,

a fan and so on
2. Natural Convection: motion of fluid results from the density
changes in heat transfer
 Tw = 80 oC

To = 30 oC
q

Fluid flow
The rate of heat transfer :
The convection coefficient is
q  Ah(Tw  To ) a measure of how effective
a fluid is at carrying heat to
and away from the surface.
h = heat transfer coefficient
(W/m2.K)
 A= surface area (m2)
 CONVECTION HEAT TRANSFER

Metal wall
T1
T2
Cold fluid B

T3 Turbulence region

Warm fluid A
q

Turbulence absent
q = hA (T-Tw)
 FORCED CONVECTION INSIDE PIPES
 Forced convection – fluid forced to flow by pressure differences
 Types of fluid, laminar or turbulent
– great effect on heat-transfer coefficient
More turbulent– greater heat-transfer coefficient

 Reynolds number, NRe


NRe  D
where
v = velocity of fluid (m/s)

 = viscosity of fluid (Pa.s)
= density of fluid (kg/m3)
D = diameter of pipe (m)

FKKSA
 FORCED
Dimensionless CONVECTION
numbers:

 Prandtl number, NPr  Nusselt number, NNu

μ
cμ
NPr  ρ  P NNu  hD
k ρc k k
P

where

= viscosity of fluid (Pa.s)

= density of fluid (kg/m3)
k = thermal conductivity of fluid (W/m.K)
cP = heat capacity of fluid (J/kg.K)
h = heat transfer coefficient (W/m2.K)
D = diameter of pipe (m)

FKKSA
 LAMINAR FLOW INSIDE HORIZONTAL PIPE
NRe  2100 & NReNP r D  100 :
L 1
h D  3 0.14
 

N   a 1.86N N
D   b 
 Nu a k 

Re Pr L  w 
where
D = inside diameter
 of pipe (m)
Limitations
L = length of pipe (m)
b = viscosity of fluid at bulk temperature (Pa.s) N Re  2100
w = viscosity of fluid at wall temperature (Pa.s) D
N Re N Pr  100
L
ha = average heat transfer coefficient (W/m2.K)
 T  T 
T   bo bi 
All physical properties at b mean 2 except  w

 T  T    T  T 
q = haA∆Ta where ΔT   w bi   w bo 
a 2
FKKSA
 TURBULENT FLOW INSIDE HORIZONTAL PIPE
Rate of heat transfer is greater
Many industrial heat transfer processes in the turbulent region
L Limitations
NRe  6000 , 0.7 ≤ NP r ≤ 16000 &D  60:
N Re  6000
D
0.7  N Pr  16000
hLD 1  0.14
L
NNu   0.027 NRe 0.8 N 3  b 

k Pr  
 w  L
 60
D
where
 b =viscosity of fluid at bulk average temperature (Pa.s)
 w = viscosity of fluid at wall temperature (Pa.s)
k = thermal conductivity of fluid (W/m.K)
cP = heat capacity of fluid (J/kg.K)
hL = heat transfer coefficient based on the log mean driving force
∆Tlm (W/m2.K)
D = inside diameter of pipe (m)
FKKSA
 TURBULENT FLOW INSIDE HORIZONTAL PIPE
Air at 1 atm total pressure (NRe  2100) :
0.8
3.52 Limitations
hL 
D0.2 N Re  2100

Water at T = 4 to 105oC :

0.8
 
hL 1429 1 0.0146 T C 0.2 o  Limitations
 

D  T  4 to 105 o C
Organic liquids :
 0.8

hL  423
D0.2
Flow inside helical coils :

Hcoil = hstraight pipes + (1 + 3.5D/Dcoil)
where Limitations
 = velocity of fluid (m/s)
N Re  10 4
D = inside diameter of pipe (m)
FKKSA
EXAMPLE 4.5-1 Page 262: Heating of Air in
Turbulent Flow
Air at 206.8 kPa and an average of 477.6 K is being heated as
it flows through a tube of 25.4mm inside diameter at velocity
of 7.62 m/s. The heating medium of 488.7 K steam
condensing on the outside of the tube. Since the heat-transfer
coefficient of condensing steam is several thousand W/m2.K
and the resistance of the metal wall is very small, it will be
assumed that the surface wall temperature of the metal in
contact with the air is 488.7 K. Calculate the heat-transfer
coefficient for an L/D > 60 and also the heat-transfer flux
q/A.
 ho  hsteam

Tave  477.6 K
air
25.4 mm v  7.62 m/s
Tbi P  206.8 kPa
Tbo
Steam, Tw  488.7 K

From Appendix A.3, at P  101.32 kPa, Tave  Tbm  477.6 K

b  2.6 105 Pa.s
N Pr  0.686
k  0.03894 W/m
From Appendix A.3, at Tw  488.7 K
3
  0.74 kg/m
 w  2.64 105 Pa.s
For  ,
 m
PV  nRT  PV    RT
M 
m
PM    RT  PM  RT
V 
PM
   is depend on P & T 
RT
 P  T 
 2  1  2  2 
 P1  T1 
T1  T2
 206.8 
  206.8 kPa  0.74   1.509 kg/m
3

 101.35 
 D
N Re 

25.4 10 3 (7.62)(1.509) q
 hL Tw  Tbm 
 A
2.6 10 5
 63.2488.7  477.6 
 1.122  10 4 ( 6000)
 701.1 W/m 2

0.14
hL D 0. 8
1  b 
N Nu   0.027 N Re N Pr 3  
k  w 
0.14
hL (25.4  10 3 )
  0.686  0.0260 
0.8 1
 0.027 1.122 10 4 3
0.03894  0.0264 
hL  63.2 W/m 2 .K
 TRANSITION FLOW INSIDE A PIPE
2100  NRe  6000 :

where
G = mass velocity of fluid (kg/s.m2) = 

FKKSA
 EXAMPLE 4.5-2 Page 264: Water Heated by
Steam and Trial and error Solution

Water is flowing in a horizontal 1-in schedule 40 steel

pipe at an average temperature of 65.6oC and a velocity of
2.44 m/s. it is being heated by condensing steam at
107.8oC on the outside of pipe wall. The steam side
coefficient has been estimated as ho = 10500 W/m2.K.
a) Calculate the convective coefficient hi for water inside
the pipe
b) Calculate the overall coefficient Ui based on the inside
surface area
c) Calculate the heat-transfer rate q for 0.305m of pipe with
the water at an average temperature of 65.6oC
 ho  10500 W/m 2 .K

33.4 mm
water Tbm  65.6 o C
26.64 mm
Tbi v  2.44 m/s Tbo
Steam, Tw  107.8 o C

0.305 m

From Appendix A.3, at Tbm  65.5 o C,

b  0.432 10 3 Pa.s
N Pr  2.72
k  0.6629 W/m
  981.9 kg/m 3
The temperature of inside metal is needed and will be assumed as about one third
the way between 65.5 and 107.8 or 80o C for first trial, Tw  80 o C
at Tw  80 o C   w  3.56 10  4 Pa.s

D
N Re 

0.0266(2.44)(980)

4.32  10  4
 1.473 105 ( 6000)
0.14
hL D 1  
0.8
N Nu   0.027 N Re N Pr 3  b 
k  w 
0.14

 2.72  34..56 

4
hL (0.0266) 32 10
 0.8 1
 0.027 1.473 105 3 
4 
0.663 10 
hL  13324 W/m 2 .K
We have to check the assumption we make for the temperatu re again.
The various areas are as follow :

Ai  Di L Ao  Do L
  (0.0266)(0.305)   (0.0334)(0.305)
 0.0255 m 2  0.032 m 2

1 1
Ri    0.002943
hi Ai 13324(0.0255)
ln(r2 / r1 ) ln(0.0334 / 0.0266)
R pipe    0.002633
2 kL 2 (45)(0.305)

1 1
Ro    0.002976
ho Ao 10500(0.032)

 R  0.008552
The overall temperatu re difference is (107.8  65.6)  42.2 o C
The temperatu re drop across the water film is
Ri  0.002943  o
Temperatur e drop  (42.2)   (42.2)  14.5 K  14.5 C
R  0.008852 
Hence, Tw  65.5  14.5  80.1 o C.This is quite close to the original estimate of 80 o C.
Second trial is not necessary.

(b) To  Ti
q  U i Ai To  Ti 
R
1
Ui 
Ai  R
1

0.0255(0.008552)
 4586 W/m 2 .K
(c) with water at an average temperature of 65.6 o C,
To  Ti  107.8  65.6  42.2 o C
q  U i Ai To  Ti 
 4586(0.0255)(42.2)
 4935 W
 ENTRANCE-REGION EFFECT ON HEAT-
TRANSFER COEFFICIENT
At entrance, h = ∞

At L/D  60, h = hL
Limitations
0.7 L
h  1   D  2  L  20 2
D
 20
hL L
  D

h  1  6 D  20  L  60
hL L D Limitations
 
L
20   60
D
where
h = average heat transfer coefficient for a tube of finite length L
hL= heat transfer coefficient for a very long tube

FKKSA
 LIQUID METAL HEAT-TRANSFER COEFFICIENT
Turbulent flow, NRe  6000 :
L Limitations
Uniform heat flux, 100  NPe  104 & D  60 :
N Re  2100
h D L
N  L  0.625 N 0.4 D
 60
Nu k Pe
100  N Pe  10 4

Constant wall temperature ( L  60, NPe  100 ) :

D
h D
 L  5.0  0.025 N 0.8
Limitations
N
Nu k Pe L
 60
D
where N Pe  100
NPe = Peclet number = NReNPr

FKKSA
EXAMPLE 4.5-3 Page 266: Liquid-metal Heat
Transfer Inside a Tube

A liquid metal flows at a rate of 4.00kg/s through a tube

having an inside diameter of 0.05m. The liquid enters at 500K
and is heated to 505K in the tube. The tube wall is maintained
at a temperature of 30K above the fluid bulk temperature and
constant heat flux is maintained. Calculate the required tube
length. The average physical properties are as follows: μ = 7.1
x 10-4 Pa.s, ρ = 7400 kg/m3, cp = 120 J/kg.K, k = 13 w/m.K
 L?

Tbi  500 K liquid metal

Tbo  505 K Di  0.05 m
m  4 kg/s

Tw  Tbm  30 K

Ai  Di L

Tbi  Tbo 500  505 Tbm

Tbmean    502.5 K Tw  Tbm  30 K
2 2
From Appendix A.3, at Tbm  502.5 K,
q
b  7.110 4 Pa.s
Tw
c p  120 kJ/kg.K
k  13 W/m.K 
q  hATw  Tbmean   m c p Tbo  Tbi  h  or c

  7400 kg/m3
 2
D
Ax  i
Dm 4
N Re 
Ax
Tbm
0.05(4)

 
7.1 10  4   0.05 2 
4 
 1.435 105 ( 2000)
Tw

cp
N Pr  N Pe  N Re N Pr
k
 1.435  105 (6.55 10 3 )
120(7.1 10  4 )
  940  (100  N Pe  10 4 )
13
 6.55  10 3
 hi Di 0.4
N Nu   0.625 N Pe
k
hi (0.05)
 0.625(940) 0.4
13
hi  2512 W/m 2 .K

q  m c p Tbo  Tbi  Ai  Di L

2
 4(120)(505  500) 3.185  10   (0.05) L
 2400 W L  0.203 m

q 2400
 hi Tw  Tbmean  
Ai Ai
2400
2512(30) 
A
2
Ai  3.185  10 m 2
 q  U i Ai Tbm  U o Ao Tbm

q  m c p h Tho  Thi   m c p c Tco  Tci 

T1  T2 T2  T1

Tlm  
 T1   T2 
ln  ln 
 T2   T1 
 Thi
Tho
Thi Tho T1
Tco Tci Tco T2

Tci
countercurrent flow

Thi
Thi Tho Tho
T1
Tci Tco T2
Tco
Tci
parallel flow
  Tbi  Tbo 
q  ha ATa  hai Ai  Tw  
 2 

 
 
 T1  T2 
q  ha ATlm  hai Ai
  T1  
 ln  
  T2  
 EXAMPLE 4.5-4 Page 268: Heat Transfer Area and
Log Mean Temperature Difference

A heavy hydrocarbon oil which has a cpm = 2.30kJ/kg is

being cooled in a heat exchanger from 371.9 K to 349.7 K
and flows inside the tube at a rate of 3630 kg/h. A flow of
1450kg water/h enters at 288.6K for cooling and lows
outside the tube.
a) Calculate the water outlet temperature and heat-transfer
area if the overall Ui = 340 W/m2.K and the streams are
countercurrent
b) Repeat for parallel flow
 (a) countercurrent flow

397.1 K  Thi
oil, m  3630 kg/h c 
p oil  2.3 kJ/kg.K
T1 Tho  349.7 K c 
p water  4.187 kJ/kg.K
Tco
T2 U i  340 W/m 2 .K
Ai  ?
Tci  288.6 K

water, m  1450 kg/h

q  m c p h Tho  Thi  q  m c p c Tco  Tci 

 3630(2.3)(371.9  349.7)/ 3600 51490  1450(4.187)(Tco  288.6)
 51490 W Tco  319.1 K
T1  371.9  319.1  52.8 K
T2  349.7  288.6  61.1 K

T1  T2 61.1  52.8

Tlm    56.9 K
 T1   61.1 
ln  ln 
 T2   52.8 

q  U i Ai Tlm
51490  340 Ai (56.9)
Ai  2.66 m 2
 (b) parallel flow

T1  349.7  319.1  30.6 K

T2  371.9  288.6  83.3 K

T1  T2 83.3  30.6

Tlm    52.7 K
 T   83. 3 
ln 1  ln 
 T2   30.6 

q  U i Ai Tlm
51490  340 Ai (52.7)
Ai  2.87 m 2

This is a larger area than for counterflow. This occurs because counterflows gives
larger temperature driving forces.
EXAMPLE 4.5-5 Page 269 : Laminar Heat
Transfer and Trial and Error

A hydrocarbon oil at 150oF enters inside a pipe with an

inside diameter of 0.0303 ft and a length of 15 ft with a
flow rate of 80 Ibm/h. The inside pipe surface is assumed
constant at 350oF since steam is condensing outside the
pipe wall and has a very large heat-transfer coefficient.
The properties of the oil are cpm= 0.5 btu/Ibm.oF and km =
0.083 btu/h.ft.oF. The viscosity of the oil varies with
temperature as follows: 150oF, 6.50 cp; 200oF, 5.05 cp;
250oF, 3.80 cp; 300oF, 2.82 cp; 350oF, 1.95cp. Predict the
heat-transfer coefficient and the oil outlet temperature, Tbo
 15 ft

Tbi  150 o F
Tbo  ? 0.0303 ft
c 
p oil  0.5 btu/Ibm.o F
oil m  80 Ibm/h k m  0.083 btu/h.ft.o F

D 2 Tw  350 o F
Ax 
4

Assume value if Tbo  250 o F

250  150
Tbmean   200 o F
2
 2.4191 Ib/ft.h 
  5.05cp   12.23 Ib/ft.h
 1cp 
 Dm
N Re 
Ax
0.0303(80)

 
12.23  0.03032 
4 
 275.5( 2100)

cp
N Pr 
k
0.5(12.23)

0.083
 73.7

D  0.0303 
N Re N Pr  275.5(73.7)   41
L  15 
 1 0.14
hD  D   
3
N Nu   1.86 N Re N Pr   b 
k  L   w 
0.14
h(0.0303) 1
 12.23 
 1.86413  
0.083  1 .95  2 .4191 
h  20.1 btu/h.ft 2 .o F

 We have to check the assumption we make for the temperature again.

q  m c pm Tbo  Tbi   80.0(0.5)Tbo  150

q  ha ATa
Tbi  Tbo  150  Tbo 
Ta  Tw    350    275  0.5Tbo
2  2 
 q  m c pm Tbo  Tbi   ha ATa
80.0(0.5)Tbo  150  275  0.5Tbo
Tbo  255 o F

This is higher than the assumed value of 250 o F. For the second trial, the mean bulk temperature
of the boil would be (150  255)/2 or 202.5 o F. The new viscosity is 5.0 cp compared with 5.05 for
first trial. Hence, the outlet temperature of T1  255 o F is correct.
 Dm
N Re 
Ax
0.0303(80)

 
12.23  0.03032 
4 
 275.5( 2100)

cp
N Pr 
k
0.5(12.23)

0.083
 73.7

D  0.0303 
N Re N Pr  275.5(73.7)   41
L  15 
 1 0.14
hD  D   3
N Nu   1.86 N Re N Pr   b 
k  L   w 
0.14
h(0.0303) 1
 12.23 
 1.86413  
0.083  1.95  2.4191 
h  20.1 btu/h.ft 2 .o F

 We have to check the assumption we make for the temperature again.

q  m c pm Tbo  Tbi   80.0(0.5)Tbo  150

q  ha ATa

Tbi  Tbo  150  Tbo 

Ta  Tw    350    275  0.5Tbo
2  2 
 q  m c pm Tbo  Tbi   ha ATa
80.0(0.5)Tbo  150  275  0.5Tbo
Tbo  255 o F

This is higher than the assumed value of 250 o F. For the second trial, the mean bulk temperature
of the boil would be (150  255)/2 or 202.5 o F. The new viscosity is 5.0 cp compared with 5.05 for
first trial. Hence, the outlet temperature of T1  255 o F is correct.
 1
m
N Nu  CN Re N Pr 3 C & m from table 4.6 -1

The fluid properties are evaluatedat the film temperature, T f  Tw  Tb  / 2,

where Tw is the surface or wall temperature and Tb the average bulk fluid temperature
 Limitations
1
0.5
N Nu  0.664 N Re N Pr 3 N Re  3  10 5
N Pr  0.7

1 Limitations
0.8
N Nu  0.0366 N Re N Pr 3
N Re  3  10 5
N Pr  0.7
 EXAMPLE 4.6-1 Page: 272 Cooling a Copper Fin

A smooth, flat, thin fin of copper extending out from a

tube is 50 mm by 51 mm square. Its temperature is
approximately uniform at 82.2oC. Cooling air at 15.6oC
and 1 atm abs flows parallel to the fin at a velocity of
12.2 m/s.
a) For laminar flow, calculate the heat-transfer coefficient,
h
b) If the leading edge of the fin is rough so that all of the
boundary layer o film next to the fin is rough so that alls
o the boundary layer or film next to the fin is completely
turbulent, calculate h
 q Tw  82.2 o C

air, v  12.2 m/s

Tbi  15.6 o C
P  1 atm 51 mm

51 mm L
N Re 
Tw  Tb 82.2  15.6 
Tf    48.9 o C  49 o C
2 2 51 10 3 (12.2)(1.097)

1.95  10 5
From Appendix A.3, at T f  49 o C,
 3.49 10 4 ( 3 105 )
b  1.95  10 5 Pa.s
N Pr  0.704 hL 0.5
1
N Nu   0.664 N Re N Pr 3
k  0.028 W/m.K k
1
  1.097 kg/m 3 h(51 10 3 )
 0.664(3.49 10 4 ) 0.5 (0.704) 3
0.028
h  60.7 W/m 2 .K
q  hATw  Tbm 
 60.7(51 10 6 )82.2  15.6
 10.51 W
 Limitations
1
0.5
N Nu  2  0.60 N Re N Pr 3 N Re  1 to 70000
N Pr  0.6 to 400
EXAMPLE 4.6-2 Cooling of a Sphere

Using same condition as Example 4.6-1, where air at 1 atm

abs pressure and 15.6oC is flowing at velocity of 12.2 m/s,
predict the average heat-transfer coefficient for air flowing
by a sphere having a diameter of 51mm and an average
surface temperature of 82.2oC. Compare this with the value
of h = 77.2 W/m2.K for the flat plate in turbulent flow.

Tw  82.2 o C Tw  Tb 82.2  15.6

Tf    48.9 o C  49 o C
2 2
From Appendix A.3, at T f  49 o C,

51 mm b  1.95  10 5 Pa.s
N Pr  0.704
k  0.028 W/m.K
  1.097 kg/m 3
 L
N Re 

51 10 3 (12.2)(1.097)

1.95  10 5
 3.49 10 4 ( 3 105 )

hD 0.5
1
N Nu   2  0.60 N Re N Pr 3
k
1
h(51  10 3 ) 4 0.5
 2  0.60(3.49  10 ) (0.704) 3
0.028
h  56.1 W/m 2 .K
EXAMPLE 4.6-3 Page 273: Heating Air by a Bank of
Tubes

Air at 15.6oC and 1 atm abs flows across a bank of tubes

containing four transverse rows in the direction of flow and 10
rows normal to the flow at a velocity of 7.62 m/s as the air
approaches the bank of tubes. The tube surfaces are maintained
at 57.2oC. The outside diameter of the tubes is 25.4mm and the
tubes are in-line to the flow. The spacing Sn of the tubes normal
to the flow is 38.1mm and also Sp is 38.1mm parallel to the
flow. For a 0.305m length of the tube bank, calculate the heat-
transfer rate
 1 2 3 4 D  25.4 mm
air, v  7.6 m/s
Tbi  15.6 o C 2
S n  38.1 mm
P  1 atm 3

10
From Appendix A.3, at T f  37.7 o C,
S p  38.1 mm  b  1.904  10 5 Pa.s
Tw  57.2 o C N Pr  0.705
Tw  Tb 57.2  18.3 k  0.027 W/m.K
Tf    37.7 o C
2 2   1.137 kg/m 3
 vS n  38.1 
v max   7.6   22.86 m/s
Sn  D  38.1  25.47 

L max 
N Re 

0.02547(22.86)(1.137)

1.90  10 5
 3.47  10 4 ( 3  10 5 )

From Table 4.6 - 2 (pg 251)

Sn Sp
In line,   1.5  c  0.278, m  0.620
D D
 hD m
1
N Nu   cN Re N Pr 3
k
1
h(0.0254)
 0.278(3.47  10 4 ) 0.620 (0.705) 3
0.027
h  171.8 W/m 2 .K

This h is for 10 rows. For only 4 rows in the transverse direction, the h must be multiplied by 0.9,
as given in Table 4.6 - 3

 h  0.9(171.8)  154.62 W/m 2 .K

A  40DL  40 (0.0254)(0.305)  0.973 m 2

At  10 S n L  10(0.0381)(0.305)  0.1162 m 2

m  vAt (3600)  7.6(1.224)(0.1162)  1.084 kg/s

  T  Tbi 
q  hA Tw  bo   m c p Tbo  Tbi 
 2 
 T  15.6 
154.62(0.973) 57.2  bo   1.084(1.0048  10 3 )(Tbo  15.6)
 2 
Tbo  20 o C

If second trial ware to be made, the new average Tb to be use would be (15.6  20)/2 or 17.8 o C
 2
Limitations
 h  cp  3
2.876 0.3023
    0.35
Gases
c p '   k  f N Re N Re N Re  10 to 10000

Note : All properties are at Tbmean, except for those with

subscript f