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Handbook of
Burner Technology for
Industrial Furnaces
Fundamentals | Burner | Applications
2nd Edition
3. Heat transfer 31
3. Heat transfer
Ulrich Renz
32 3. Heat transfer
3. Heat transfer
Ulrich Renz
(3.1)
The minus sign indicates that the heat flows in the direction of the temperature gradient.
3. Heat transfer 33
In order to determine the heat flow quan- Table 3.1: Thermal conductivity of selected materials
titatively, the thermal conductivity must be at 0 °C
known. In gases the thermal conductivity
Thermal
is determined by the collisions of the gas
Materials conductivity
molecules, where the kinetic energy of a
h (W/mk)
gas molecule is presumed proportional
to its temperature. Moving from one area Metals
of higher temperature to an area of lower Silver 410
temperature, the molecule loses part of its
energy and momentum through collisions. If Copper 385
we assume the gas to be a continuum then Carbon-enriched steel 43
we can consider this process a process of
Chromium-Nickel-enriched
heat conduction in gases. 16
steel 3
For simple gas molecules and moderate Non-metallic solids
temperatures the thermal conductivity can
be calculated on the basis of the kinetic Quartz 2.4
theory. On the other hand, liquids and solids Sand-rock 1.8
require more precise assumptions than the
above theoretical premises so that in gen- Window glass 0.8
eral the values of the thermal conductivity Liquids
are determined experimentally.
Mercury 8.21
Table 3.1 lists a few thermal conductivity
Water 0.56
constants to show the order of their values
for different mediums. Cooling agent R 12 0.07
It is generally known that a hot object cools Gases
faster when it is being blown upon as com- Hydrogen 0.175
pared to it being left to freely cool down in
open air. The heat conductivity mechanism Air 0.024
on the part of the air side of the system is Water vapor 0.021
additionally reinforced with the mechanism
of heat transfer through the macroscopic air
flow along the body (Figure 3.2). The intensity of this so-called convective heat transfer is pro-
portional to the temperature difference between the body surface area and the cooling medium.
The proportionality constant – the convection heat-transfer coefficient _ – depends on many pa-
rameters such as the flow velocity, the medium type, etc. Even so, the convection heat-transfer
coefficient can be determined theoretically in the simplest cases using the principles of flow dy-
namics. Yet, in many real world situations, it can only be determined experimentally.
34 3. Heat transfer
The order of magnitude of the convection heat-transfer coefficient is listed in Table 3.2.
In industrial furnaces these three basic mechanisms of heat transfer happen simultaneously. The
heat transmission inside the load occurs by heat conduction. Natural convection and radiation
cool the outer furnace wall. The heat transfer from the hot inside furnace walls to the load takes
place by radiation and convection, whereas radiation is clearly dominant at higher furnace temper-
atures. At lower furnace temperatures or low emissivity of the load, heat transfer can be increased
by a targeted flow configuration to increase forced convection. Very high convective heat transfer
coefficients can be achieved with impingement systems (see Figure 3.3). Depending on the nozzle
configuration, convective heat transfer coefficients of well over 100 W/m2K are possible. Impinge-
ment systems are used for heating and defined cooling.
3. Heat transfer 35
taken into account. In spite of the fact that in most heat transfer problems energy is simultaneously
transported through conduction and/or convection and radiation, we will deal henceforth, as far as
possible, with radiation only.
Figure 3.4 shows the electromagnetic spectrum and the wavelengths at which heat radiation takes
place.
(3.2)
(3.3)
36 3. Heat transfer
Planck’s distribution law for monochrome or spectral radiation flux in a narrow wavelength band
d,h is defined as follows:
(3.4)
C2 = 1.439 · 10-2 mK
with:
l(h) – spectral reflectivity Figure 3.6: Contributions to radiative transport
3. Heat transfer 37
• Solids, which fully absorb all radiation have already been defined as “black bodies”
3
_(h) = _= 1 (3.8)
• “Grey” bodies, on the other hand, are bodies with radiation properties that are independent of
the wavelength (_(h) = _, l(h) = l, o(h) = o) and which radiate in all directions (diffuse radiation)
l+_+o=1 (3.9)
_=¡ (3.11)
Strictly speaking, Kirchhoff’s law is valid only for monochromatic radiation, i.e.
Therefore, Kirchhoff’s law, defined for the total emissivity ¡ and total absorptivity _, may not always
be valid since the incident and emitted radiation are not equally dependent on the temperature and
spectral distribution.
Two special cases should be mentioned though, for which Kirchhoff’s law for the total radiation
properties remains valid.
• The radiating body is a black or grey body whose temperature is equal to that of the investi-
gated body, Trad = Tbody
• The surfaces of the body are grey, i.e. their absorptivity is independent of the wavelength.
Especially the second case is of importance since for many practical purposes this holds true.
If a high level of accuracy is required, then a precise knowledge of the monochromatic radiation
properties is necessary.
Figure 3.7 shows the radiative power of an actual real body at T = 2,000 K. The results of Planck’s
distribution law, equation (3.4), for a black and a grey body are given as a comparison.
38 3. Heat transfer
3. Heat transfer 39
Figure 3.8: Emissivity as a function of the emitting direction of selected materials, according to Eckert
The view factor F12 is that portion of the radiation that originates from the area A1 and which hits
the surface area A2:
(3.13)
40 3. Heat transfer
(3.15)
for cases where only black bodies are involved. Then the radiative power consists only of emitted
radiation, for which the Stefan-Boltzmann law equation is valid. As an example, Figure 3.10 shows
how the view factors can be determined for radiation transfer between perpendicular plates.
3. Heat transfer 41
radiation transfer as a function of the temperature of the bodies. For grey bodies on the other hand,
the surface brightness includes not only the emitted but also portions of the reflected and transmit-
ted radiation since, unlike black bodies, the incident radiation is not fully absorbed.
Thus, for the radiation transfer between two non-transmissive solids
(3.16)
where e.g.
(3.17)
3
The solution methods for these equations are normally rather complex. Yet, for a number of simple,
often encountered geometries, complete relationships for the radiation transfer can be derived.
(3.18)
(3.19)
and accordingly:
(3.20)
42 3. Heat transfer
(3.21)
which can also be written as a function of the body temperature using the Stefan-Boltzmann law:
(3.22)
(3.23)
In the case of enclosed bodies, the view factor \12 has the value 1 and thus
(3.24)
3. Heat transfer 43
For the heat emitted from body 2 we get additionally parts of the reflected radiation, which origi-
nate from the surface brightness of the body itself – in other words “the body sees itself”.
(3.25)
(3.26)
3
The equations are used to determine the surface brightness of both bodies, which after substitut-
ing and several transformations give a relationship for the radiation transfer
(3.27)
44 3. Heat transfer
Figure 3.13: Heat flow rate per unit area as a function of the temperature difference
The negative sign, as implied by the second law of thermodynamics, indicates that heat can only
flow from regions of higher to regions of lower temperature.
(3.29)
In case of a composite wall, i.e. consisting of many layers with different thickness and materials,
the equation must be calculated for each section in turn. The heat entering section 1 flows un-
changed out of section 3 for steady state, one-dimensional cases (see Figure 3.14).
3. Heat transfer 45
It follows:
(3.30)
(3.31)
using the temperature gradient in the fluid and the thermal conductivity hfl as parameters.
and thus
(3.32)
46 3. Heat transfer
This differential equation can be integrated using the boundary condition (t = 0, T = T0, i.e. e* = 0)
for 0 ) e* ) 1 which finally gives
(3.33)
We can express the equation (3.33) introducing two dimensionless numbers, namely the Biot
number
Bi = _ L / h (3.34)
where L is the characteristic length, resulting from the ratio V/A, in the form of:
(3.36)
In other words, the temperature history of a body (Figure 3.16) with high thermal conductivity
and its surrounding is in general the same for all problems where the boundary conditions are
described by equal Biot numbers.
Moreover, this is valid for all problems where the Biot number is very small, Bi << 1. Equation (3.36)
may still be used as a first approximation of the heat transfer behavior of a body in cases where
the above conditions do not apply.
In cases where the thermal resistance within a body cannot be neglected, a general, analytical
solution is possible only after complex calculations and only for a limited number of geometries
and boundary conditions.
3. Heat transfer 47
3
3.4 Convection
We discussed the energy transport by heat conduction in chapter 3.3. A key role is assigned to the
molecular properties, described by the thermal conductivity of the material.
In some of the energy transport examples discussed previously we had to formulate the bound-
ary conditions for heat transfer from the body to the flowing fluid along the body. Without detailed
analysis of the physical relationships, we assumed that the heat transfer coefficient _ was as-
sumed to be known. In this section we will discuss the basic principles of this transport mechanism
(see Figure 3.17).
The major difference between the transport mechanisms of heat conduction and heat convection
can be demonstrated by a simple experiment, where a hot, horizontal wall is allowed to cool down
(Figure 3.18).
In the first experiment, the wall is cooled from below by a cold fluid, liquid or gas. For this arrange-
ment we have a stagnant fluid and the heat is transported solely by conduction to the area of lower
heat.
48 3. Heat transfer
If we change the arrangement in such a way that the hot wall is placed at the bottom, then the fluid
will become unstable and the warmer areas (in the lower part) will rise up due to their lower density
and hence flow in the fluid will be initiated. This so-called natural convection amplifies the heat
transfer. In the third case shown (right most diagram), the hot wall is cooled by a medium, which
is pumped through the system. As was the case of natural convection, once again, in this case of
forced convection, it is not only the thermal conductivity of the fluid that determines the charac-
teristics of the heat transfer. An important, additional parameter that dictates the heat transfer is
obviously the velocity of the fluid, which depends both on the density differences as well as the
electrical power of the pump.
To determine the heat transfer coefficient _, a Nusselt number correlation is given in the next
chapter exemplary.
3. Heat transfer 49
50 3. Heat transfer
(3.42)
with the constant C relevant for the given ranges of Reynolds numbers and m (Table 3.3).
Red C m
0.4 – 4 0.989 0.330
4 – 40 0.911 0.385
40 – 4,000 0.683 0.466
4,000 – 40,000 0.193 0.618
40,000 – 400,000 0.0266 0.805
(3.43)
Figure 3.20: Mean Nusselt number for circular cylinders in a flow perpendicular to their longitudinal axis