Engine Cooling System – HEX/Radiator: Design / Analysis

Radiator Design and Analysis  The approach depends on whether the task is to rate or size a HEX
 Rating means to evaluate the performance of a HEX when the size
is specified. This is a performance analysis problem where the HEX
 To perform the tasks of radiator/HEX design type & size are known, and the fluid outlet temperatures are desired.
or analysis, you need to recapitulate the  Sizing refers to determining the dimensions of a HEX to meet a
background engineering of Heat Transfer, Fluid specified performance. This is a design problem where the capacity
Mechanics, and Thermodynamics that relate the rate and temperatures are known, and it is desired to size the HEX.
Energy balance, Rate equation, Overall heat  We have two procedures for performing a HEX design/analysis
transfer coefficient etc. task: the LMTD method and the e-NTU method. For any problem,
rating or sizing, both methods may be used to obtain similar results.
 In Sizing problem: Use of the LMTD method is facilitated by the
knowledge of the hot and cold fluid inlet and outlet temperatures.
The corresponding values of the q and A may be computed from the
energy balances.
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be shared outside of the Blackboard Learn-University of Windsor platform." be shared outside of the Blackboard Learn-University of Windsor platform."
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Engine Cooling System – HEX/Radiator: Design/Analysis (Contd..) Engine Cooling System – Radiator Analysis

 In Sizing problem: Of course the e-NTU method may also be used

Energy Balance, Rate Equation, Overall Coefficient:
to obtain A by first calculating the e and Cmin/Cmax. The appropriate
chart or equation may then be used to obtain the NTU value, which in  To predict the performance of a radiator, it is necessary to relate
turn may be used to determine A. the total heat transfer rate to parameters such as fluid flow rates,
inlet and outlet fluid temperatures, the overall heat transfer
 In Rating problem: Although the LMTD method may be used for coefficient, and the total surface area for heat transfer.
HEX rating problem (i.e for performance calculation), the
computations would be tedious, requiring many iterations. So, these Energy Balance:
problems are best be analyzed by using e-NTU method. From conservation of energy we have:
For waterside: Q  mw cp,w Tw,i  T w,o 
HEX Rating:
 The objective of a HEX rating problem is to verify whether the For airside: Q  ma cp,a  Ta,o  T a,i 
performance of an existing HEX design is adequate to meet the
where mw cp,w  C w ma cp,a  Ca
required vehicle specification.
are the capacity rates (W/k).
"The lecture presentations and slides are provided for educational purposes in this course. No part of them should "The lecture presentations and slides are provided for educational purposes in this course. No part of them should
be shared outside of the Blackboard Learn-University of Windsor platform." be shared outside of the Blackboard Learn-University of Windsor platform."
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Engine Cooling System – Radiator Analysis Engine Cooling System – Radiator Analysis
The convection rate equation:
Another expression for relating the heat rate to an appropriate The overall heat transfer coefficient may be expressed as:
temperature difference between air and water is
1
 Rconv, w  Rwall  Rconv, air
Q  UATLm UA
or
where
1  1   1 
   Rw   
is an appropriate mean temperature difference, U is overall UA  hA  w  hA  a
heat transfer coefficient and A is the radiator surface area.
This expression depends upon the radiator configuration, and Note that the calculation of the UA can be based on the
flow conditions, as well as physical dimensions. water or the airside since
1 1 1
The overall coefficient:  
UA U w Aw U a Aa
The convection rate equation can be represented by the
thermal circuit in terms of the convection thermal resistances The convection coefficients for the waterside and airside can
on the water and air sides, and the wall conduction resistance. be estimated using empirical correlations appropriate for the
flow geometry and conditions.
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be shared outside of the Blackboard Learn-University of Windsor platform." be shared outside of the Blackboard Learn-University of Windsor platform."
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1
 Engine Cooling System – Radiator Analysis Engine Cooling System – Example
The conduction resistance R w is obtained for a plane wall or for a Example:
cylindrical wall.
A test is conducted to determine the overall H. T. coefficient in an
A typical automotive radiator is considered to be a cross-flow automotive radiator that is a compact cross-flow water-to-air HEX with
heat exchanger type. These radiators can be analyzed using the both fluids (air+water) unmixed. The radiator has 40 tubes of internal
fluid energy balance and convection rate equation with diameters 0.5 cm and length 65 cm in a closely spaced plate–finned
correction applied to the value of ΔTLm, CF that would be matrix. Hot water enters the tubes at 90C at a rate of 0.6 kg/s and
computed under the assumption of counter flow conditions. leaves at 65 C. Air flows across the radiator through the inter-fin
spaces and is heated from 20C to 40C. Determine the overall heat
TLm  F TLm ,CF
transfer coefficient Ui of this radiator based on the inner surface area
Here, Lm = log mean temperature difference of the tubes.
F = Correction factor
Soln.:
CF = Counter flow
90  65
The values of correction factor, F for common cross-flow HEX Waterside bulk/average temperature, Tavg   77 .5 C
2
configurations are given in a Heat Transfer Textbook.
Sp. Heat of water, Cp,w @ T_avg = 4.195 kJ/kg.C (i.e. at 77.5C)
"The lecture presentations and slides are provided for educational purposes in this course. No part of them should "The lecture presentations and slides are provided for educational purposes in this course. No part of them should
be shared outside of the Blackboard Learn-University of Windsor platform." be shared outside of the Blackboard Learn-University of Windsor platform."
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Engine Cooling System – Example Engine Cooling System – Example

Soln. (Contd..): Soln. (Contd..):

Heat transfer rate (Q):

The overall Heat transfer coefficient based on inner surface area (Ui):

Q  m w c p,w T w, in  Tw, out  Q
Ui  .......... ....... (1)
kJ Ai F Δ TLm, CF
 (0.6 kg/s) (4.195 ) [(90 - 65) C]

kg. C
 62 .93 kW The Log-Mean Temperature difference
for a counter flow HEX is given by:
The waterside heat transfer area (i.e. surface area):
Δ T1  Δ T2
Δ TLm, CF  LMTD 
Aw  Aw, i  n  Di L  40  0.005 m 0.65 m   0.408 m
2
Δ T1
ln
Δ T2
We know, the heat transfer rate can also be written as: For this example,
This term is the Log-Mean Temperature difference Δ T1  Tw, in  Ta, out  (90 - 40)  50 C
Q  U i Ai F Δ TLm, CF (LMTD) for the counter flow HEX
Δ T2  T w, out  Ta, in  (65 - 20)  45 C
This is a correction factor applied when a counter flow LMTD is used for a cross flow case
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be shared outside of the Blackboard Learn-University of Windsor platform." be shared outside of the Blackboard Learn-University of Windsor platform."
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Engine Cooling System – Example

F Charts for Common Shell-and-Tube
Soln. (Contd..):
and Cross-Flow Heat Exchangers.
50  45 Shell and Tube Heat Exchanger Cross Flow Heat Exchanger
So, the LMTD is calculated as: ΔTLm, CF   47.6 C
50
ln
45
To find the correction factor “F”, we have to use temperature ratios
(F vs. P & R) charts, which can be found under heat exchanger chapter in
any Heat Transfer Textbook. In our case, the temperature ratios are:
t 2  t1 65  90 T1  T2
P   0.36 and R  0.80
T1  t1 20  90 t 2  t1

With these P & R values, we find a correction factor of, F = 0.97

Now, from Equation (1), the overall heat transfer coefficient are
calculated to be: 62930 W W
Ui   3341 [Ans.]
2 2
(0.408 m ) (0.97) (47.6) m . C
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be shared outside of the Blackboard Learn-University of Windsor platform." be shared outside of the Blackboard Learn-University of Windsor platform."
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