Lecturer:

•Dr. Hala Mahmoud

Prerequisite Courses:
•Heat transfer

Ref. Text
Fundamentals of Heat Exchanger Design. Ramesh K. Shah and Dušan
P. Sekulic Copyright © 2003 John Wiley & Sons, Inc.Notes

1
 Grading

Grading will be based on the following distribution:

Written examination (Final) 40 marks
Mid-Term Examination 20 marks
Assignments/class work 10 marks
Effective attendance 10 marks
Quiz 10 marks
Report 10 marks

HINTS

*Data book will be given and will be used along the term and Final Exam,
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3
HEAT TRANSFER EXAMPLES

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5
HEAT TRANSFER FROM EXTENDED SURFACES

• Extended surfaces may exist in many situations but are commonly

used as fins to enhance heat transfer by increasing the surface
area available for convection (and/or radiation).

37
TYPICAL FIN CONFIGURATIONS

38
 Chapter 3

FINS IN HEAT EXCHANGERS

 Widely used to achieve large heat rates per unit volume, particularly when one or
both fluids is a gas.
 Characterized by large heat transfer surface areas per unit volume (>700 m2/m3),
small flow passages, and laminar flow.
 FINS OF UNIFORM CROSS-SECTIONAL AREA
Assuming one-dimensional, steady-state conduction in an extended surface of
constant conductivity and uniform cross-sectional area with negligible
generation and radiation, the fin equation is of the form:

d 2T hP
2
 (T  T )  0 (3.6.1)
dx kAc

where p is the fin perimeter

Define:

  T ( x )  T

 b  Tb  T

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 BOUNDARY CONDITIONS
Case A
• At the base T = Tb or
(0)=b
• At the tip:
Case A: Convection heat
transfer
Case B: Adiabatic tip
Case C: Prescribed
temperature, (L)=L
Case D: Infinite fin,
T(L)=T or (L)=

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SOLUTIONS OF DIFFERENTIAL EQUATION

(3.6.2) qf  hPkAc (Tb  T )

41
Zero thermal resistance or infinite
thermal conductivity (Tfin = Tb)

12
 FIN PERFORMANCE
 Fin effectiveness: Ratio of the fin heat transfer rate qf to the heat transfer rate
that would exist without the fin

qf where b=Tb-T, and Ac,b is the fin cross-

f  (3.6.3) sectional area at the base
hAc ,b b
 f should be as large as possible (at least >2)

• For a very long (infinite) fin (Case D boundary condition):

1/ 2
 kP  (3.6.4)
 f   
 hAc 

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 External Flow

EMPIRICAL CORRELATIONS
 Generally

Nu L  C ReLm Pr n (7.1)

 Fluid properties are usually evaluated at the film temperature:

Ts  T
Tf  (7.2)
2
 Sometimes all properties are evaluated at T and the RHS of eq.
(7.1) is multiplied by

(Pr / Prs )r or (   / s )r

14
 External Flow
PROCEDURE FOR CALCULATIONS
1- Outside Convection Heat Transfer Coefficient

• Begin by recognizing the flow geometry (i.e. flat plate,

sphere, cylinder etc.)
• Specify appropriate reference temperature for evaluation of
fluid properties (usually film temperature, equation 7.2)
• Calculate Reynolds number – determine whether flow is
laminar or turbulent
 Reminder: Transition criteria:

uL VD 5 Cylinders and

ReL   5  105 Flat plates Re D   2  10 spheres
 
• Decide whether a local or average heat transfer coefficient is required
• Use appropriate correlation to determine heat transfer coefficient
• Proceed with other calculations, such as determination of heating or
cooling rate

15
 External Flow

FLAT PLATE IN PARALLEL FLOW

Laminar Flow
 Blasius solution:
hx x
Nu x   0.332 Re1x/ 2 Pr 1 / 3 , Pr  0.6 (7.3)
k
h x
Nu x  x  0.664 Re1x/ 2 Pr 1 / 3 , Pr  0.6 (7.4)
k

 For Pr<0.05, Pe=Re Pr >100: Nu x  0.565 Pex0.5 (7.5)

 For all Pr numbers, Churchill and 0.3387 Re1x/ 2. Pr 1 / 3

Nu x  Pe x  100
Ozoe correlation [1  (0.0468 / Pr)2 / 3 ]1 / 4
Nu x  2Nu x
(7.6)

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 External Flow

FLAT PLATE IN PARALLEL FLOW

Turbulent Flow

Nu x  0.0296 Re 4x / 5 Pr 1 / 3 , 0.6  Pr  60 (7.7)

Mixed boundary layer conditions

Nu L  (0.037 Re L4 / 5  871) Pr 1 / 3 0.6  Pr  60, 5  10 5  Re L  108

(7.8a)

Simplifies to: Nu L  0.037 Re L4 / 5 Pr 1 / 3 for ReL>>5x105

(7.8b)

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 External Flow

FLOW AROUND CYLINDERS AND SPHERES

• Flow around cylinders and spheres is characterized by
boundary layer development and separation.
• Heat transfer coefficients are strongly influenced by the
nature of boundary layer development at the surface.

VD
 Laminar boundary layer for Re D   2  10 5

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CYLINDER IN CROSS FLOW
(CONT.)

– Separation occurs when the velocity gradient du / dy y0

reduces to zero.

and is accompanied by flow reversal and a downstream wake.

– Location of separation depends on boundary layer transition.

VD VD
Re D  
 
 External Flow

CROSSFLOW AROUND CYLINDERS

1. Zhukauskas correlation:
1/ 4
hD  Pr 
Nu D   C Re mD Pr n  
 0.7  Pr  500, 1  Re D  10 6 (7.9)
k  Prs 
where C and m are listed in Table 7.4, (n=0.37 for 10Pr) and (n=0.36 for
10<Pr). Properties evaluated at T , except Prs which is evaluated at Ts.
2. Churchill and Bernstein correlation, for all ReD and Pr>0.2
4/5
0.62 Re1D/ 2 Pr 1/ 3   Re 
5/8 
Nu D  0.3  1   D
  (7.10)
1  0.4 / Pr  
2 / 3 1/ 4   282,000   Properties evaluated at film
temperature
3. Hilpert correlation, can be used for cross flow around other non-
circular shapes – see Table 7.3 for values of C and m

Nu D  C Re mD Pr1/ 3 (7.11)

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 External Flow

CROSSFLOW AROUND SPHERES

• Whitaker correlation:
1/ 4 0.71  Pr  380
0.4   
Nu D  2  (0.4 Re D  0.06 Re D ) Pr  
1/ 2 2/3 (7.12)
   4
 s  3. 5 Re D 7. 6 10

where properties are evaluated at T , except s which is evaluated at Ts

• Correlation by Ranz and Marshall for heat transfer from freely falling
liquid drops:

Nu D  2  0.6 Re1D/ 2 Pr1/ 3 (7.13)

 At ReD=0, equations (7.12) and (7.13) reduce to:

 Applicable for heat transfer to a
Nu D  2 stationary infinite medium around
the surface
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 External Flow

OTHER APPLICATIONS

Flow around tube banks

Packed beds

Impinging jets

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 External Flow

FLOW ACROSS BANKS OF TUBES

 Several correlations exist

 Usually of the form

Nu D  C ReDm,max Pr b

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TUBE BANKS
External Flow
Flow Across Tube Banks
• A common geometry for • Aligned and Staggered Arrays:
two-fluid heat exchangers.

ST
Aligned: Vmax  V
ST  D

   
ST
Vmax  V if 2 S D  D  ST  D
Staggered: ST  D

   
ST
or, Vmax  V if 2 S D  D  ST  D

2 SD  D 

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TUBE BANKS
(CONT.) External Flow
• Flow Conditions:

How do convection coefficients vary from row-to-row in an array?

How do flow conditions differ between the two configurations?
Why should an aligned array not be use for ST/SL < 0.7?
• Average Nusselt Number for an Isothermal Array:
Nu D  C2 C Re mD ,max Pr 0.36  Pr/ Prs  
1/ 4
 
C , m  T a b le 7 .7
C 2  T a b le 7 .8
All properties are evaluated at Ti  To  / 2 except for Prs.
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 External Flow

• Fluid Outlet Temperature (To) :

Ts  To  DNh 
 exp  
Ts  Ti  VNT ST c p 
 
N  NT x N L
What may be said about To as N  ?
• Total Heat Rate:
q  hAs Tm
As  N  DL 
T  T   Ts  To 
Tm  s i
 Ts  Ti 
n  
 Ts  To 
• Pressure Drop:  Vmax
2

p  N L   f
 2 
 , f  Figures 7.13 and 7.14

TUBE BANKS 26
(CONT.)
 27 Internal Flow

INTERNAL FLOW
 We discussed fully developed flow conditions for cases involving internal
flows, and we defined mean velocities and temperatures
 We wrote Newton’s law of cooling using the mean temperature, instead of T
q"  h(TS  Tm ) (8.5)
 Based on an overall energy balance, we obtained an alternative expression
to calculate convection heat transfer as a function of mean temperatures at
inlet and outlet.
qconv  m c p (Tm,o  Tm,i ) (8.6)
 We obtained relations to express the variation of Tm with length, for cases
involving constant heat flux and constant wall temperature

q s" P Ts  Tm,o To  PL 

Tm ( x)  Tm,i  (8.8)   exp  h (8.9)
x Ts  Tm,i Ti  m c p 
m c p  
 28 Internal Flow

SUMMARY
• We used these definitions, to obtain appropriate versions of Newton’s
law of cooling, for internal flows, for cases involving constant wall
temperature and constant surrounding fluid temperature

qconv  h As Tlm q  U As Tlm

To  Ti
Tlm  (8.10-8.12)
ln(To / Ti )
 Internal Flow

HEAT TRANSFER CORRELATIONS FOR INTERNAL FLOW

Knowledge of heat transfer coefficient is

needed for calculations shown in previous
slides.
 Correlations exist for various problems involving internal flow,
including laminar and turbulent flow in circular and non-circular tubes
and in annular flow.
 For laminar flow we can derive h dependence theoretically
 For turbulent flow we use empirical correlations
 Recall from Chapters 6 and 7 general functional dependence

NuL  f (ReL ,Pr)

Chee 318
20
 Internal Flow

LAMINAR FLOW IN CIRCULAR TUBES

1. Fully Developed Region
• For cases involving uniform heat flux:

hD
Nu D   4.36 qs"  const (8.13)
k

• For cases involving constant surface temperature:

NuD  3.66 Ts  const (8.14)

Chee 318
 Internal Flow

LAMINAR FLOW IN CIRCULAR TUBES

For constant surface temperature condition:
 Thermal Entry Length case or combined entry with
Pr≥5 0.0668( D / L) Re D Pr
Nu D  3.66  (8.15)
1  0.04[( D / L) Re D Pr]2 / 3
• Combined Entry Length case
0.14 Ts  const
 
1/ 3
 Re D Pr 
Nu D  1.86    (8.16) 0.6  Pr  5
 L/D   s  0.0044 

 9.75
s
All properties, except s evaluated at average value of mean temperature
Tm,i  Tm,o
Tm 
2
Chee 318
24
 Internal Flow

TURBULENT FLOW IN CIRCULAR TUBES

 For a smooth surface and fully turbulent conditions the Dittus –
Boelter equation may be used for small to moderate temperature
differences Ts-Tm:
0.7  Pr  160
n=0.4 for heating (Ts>Tm)
Nu D  0.023 Re 4D/ 5 Pr n
(8.17) Re D  10,000 and 0.3 for cooling (Ts<Tm)
L / D  10

• For large property variations, Sieder and Tate equation:

0.14
1/ 3  
 0.7  Pr  16,700
Nu D  0.027 Re 4D/ 5 Pr   (8.18) Re D  10,000
 s  L / D  10

All properties, except s evaluated at average value of mean temperature

Chee 318
25
 Chee 318 Internal Flow

TURBULENT FLOW IN CIRCULAR TUBES

• The Gnielinski correlation takes into account the friction factor:

(f / 8)(ReD  1000) Pr 0.5  Pr  2000

NuD  (8.19)
1  12.7(f / 8)1 / 2 (Pr 2 / 3  1) 3000  ReD  5  106
Friction factors may be obtained from the Moody diagram.

• For small Pr numbers 3x10-3≤ Pr ≤5x10-2 (i.e. liquid metals)

qS  const
NuD  4.82  0.0185Pe 0.827
(8.20)
D 100  PeD  10 4
3.6 x103  ReD  9.05  105

TS  const
NuD  5.0  0.025PeD0.8 (8.21)
PeD  100

26
 Internal Flow

NON-CIRCULAR TUBES
Use the concept of the hydraulic diameter:
4 Ac
Dh 
P

where Ac is the flow cross-sectional area and P the wetted perimeter

 See Table 8.1 textbook for typical values of Nusselt numbers for
various cross sections

Chee 318
28
Internal Flow

Chee 318
 Internal Flow

SUMMARY

 Numerous correlations exist for the estimation

of the heat transfer coefficient, for various flow
situations involving laminar and turbulent flow.
 Always make sure that conditions for which
correlations are valid are applicable to your
problem.

 Summary of correlations in Table 8.4 of

textbook
Chee 318
29