ChEA: PMD

SimuTech Project’ 22
Mentor : Sunny K. Bhagat©

Module 01: Fin Design

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Focus: Fin Design as an Application of Computational Heat Transfer
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Introduction
Somewhere or the other way, you all might be aware of Thermodynamics, and someway around, it's highly possible for
an “unknown” to correlate the thermodynamics with the most applicable applications in the Chemical Engineering
domain i.e Heat Transfer. To be very clear at the beginning of our project, Let me take some lines, to firstly clear you all
with this confusion. The “Thermodynamics” and “Heat Transfer” both are two very different domains in themselves,
though it’s very genuine for people to correlate both of these domains, the reason being very obvious the “Q(Heat)”, but
when a person thinks deeply, he/she might get the understanding that thermodynamics will let us know about the
“Quantity” of thermodynamic parameter (talking here, about the heat primarily) [Additionally, the knowledge about the
processes, whether it would happen or not]. On the other hand, Heat transfer is the domain which deals with “Time
variational heat” [Additionally, helping an engineer to model the equipment and at the same time, provide a proper
controlled analysis of heat being transferred]. I hope, by this time you could clearly differentiate between these two
clear-cut contrasting domains.

Heat Transfer Mechanisms

1. Conduction
a. Due to Molecular diffusion, vibrations, the flow of e–
b. Occurs at Microscopic (Molecular) Level with the primary driving force being Temperature difference.
c. Solids, Liquids & gases
2. Convection
a. Mixture Of Conduction & fluidic motion.
b. Solids surfaces & adjacent fluids in motion.
c. Three types : [1] Forced Convection, [2] Natural Convection [3]Additional Latent Heat Exchange as in
phase change phenomena.
3. Radiation
a. Emitted by matter at any non-zero absolute temperature.
b. Heat transfer by electromagnetic waves (Medium is not necessary & contradictory to conduction or
convection).

Dominating Laws
1. Fourier’s Law Of Conduction:
𝑑𝑇
𝑄 = − 𝑘. 𝐴. 𝑑𝑥
– (1.1)
2. Newton's Law Of Cooling:
𝑄 = ℎ. 𝐴. ∆𝑇 – (1.2)
3. Stephan’s Boltzmann Law:
4
𝑄 = ϵ. σ. 𝐴 𝑠. 𝑇𝑠 – (1.3)
k: Thermal Conductivity
h: Convection coefficient
A: Concerned Area from which heat transfer is actually taking place
𝑑𝑇
𝑑𝑥
: Temperature gradient; Ts = Surface Temperature

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 ChEA: PMD
SimuTech Project’ 22
Mentor : Sunny K. Bhagat©
ϵ : Emissivity
σ: Boltzmann constant
Q: Rate of heat transfer
∆𝑇: Ts - T∞
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Exercise 1.1.A: Check out for the units of Q, k, h, ϵ,σ
Exercise 1.1.B.a: Recall Correlation of Heat transfer equations in terms of Ohms Law (∆V = IR)
Exercise 1.1.B.b: Net resistances of series & parallel arrangement of “conducting” body?
Exercise 1.1.C: What shall be the resistance for radiation heat transfer?
Exercise 1.1.D: Which of the mediums conducts & convects faster? (Solids/liquids/gases) [Refer to some literature, to get an
approximate order of magnitudes comparison for the driving parameter to compare]
Exercise 1.1.E: Google about the dependency of convection heat transfer coeff., thermal conductivity, emissivity, and
absorptivity. Anything special you encounter for any case?
Exercise 1.1.F: What is Kirchhoff's Law of radiation?
Exercise 1.1.G: Derive an equation for net radiation heat transfer for a black body? [Hint: Think in terms of Incident heat and
emitted heat for instance for a black body]

Think!!: You must be aware of the fact that at any instance of time, we do encounter all three heat transfer phenomena primarily
(leaving some exceptions, eg: medium unsuitability or absolute Zero). Can you think of when and for what conditions one of those
modes dominates?
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General Energy Balance

A. Cartesian coordinate System
B. Cylindrical Coordinate System
C. Spherical Coordinate System
● Must refer to the supplementary sheet [Supplementary Part A]

Extended Surfaces
Extended Surfaces are surfaces that extend from an item or object in order to increase the rate of heat transmission to or
from the environment by boosting convection in the study of heat transfer. Not to ignore, conduction and radiation heat
transfer will obviously be present but not the most dominating modes of interest for studying fin (in preliminary
structures) [Obv. Assumptions are meant to be broken and we will also try the same :P]. Heat transfer rates may be
increased by raising the temperature difference between the object and the environment, increasing the convective heat
transfer coefficient/ changing conductivity, or increasing the surface area of the object and what not. But, changing these
parameters as an alternative is not always practical or cost-effective. As a result, adding extended surfaces to an object
not only increases its surface area but also provides us with the opportunity of controlled design to engineer and
re-engineer as per the need and can sometimes be a cost-effective solution to heat transfer difficulties. In addition,
through this project, we will try to explore FIN as our interested extended surface for study.
Utilities as a Fin: CPU Heat sink designs, Finned Tubes heat exchangers, Car Radiators, etc.

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 ChEA: PMD
SimuTech Project’ 22
Mentor : Sunny K. Bhagat©
Fins
Schematic: Double Pipe Heat Exchanger: Must refer to the supplementary sheet [Supplementary Part B]

General Discussion :
Primarily focusing on Convective heat transfer & Utilizing equation (1.2), It could be found that, in most of the
engineering applications, the ambient temperature (T∞) & surface temperature (Ts) is defined and fixed by some
operating conditions. However, when we talk about enhancement of Q, fragile fluctuating parameters or dynamic
control parameters looks as an option, thereby h and A s are acknowledged.
Scenario 1: Enhancing 'h' might be an option, which could be accomplished by inducing flow which could be obtained
by just adding a fan or pump, for an instance. However, as you can see, these swings might be quite dynamic in relation
to whatever output we desire, and this might be just insufficient.
Scenario 2: Enhancing the surface area of heat transfer (Attaching fins to the surface).

Fin Material : Material should be of high thermal conductivity (k), as a result of which uniform temperature is tried to
be maintained from base to the tip, such that conduction phenomena won’t dominate and more and more heat transfer
could be done by convection. [Look at the case of CPU heat sinks?]
Ideal Fin: If temperature of fin and fin base i.e. (object where fins are installed) are same, then that fin behaves as an
ideal fin. [Think in terms of k & Check k → ∞ ; for those materials]

Schematic Of Rectangular Unifin Model: Must refer to the supplementary sheet [Supplementary Part C]
Assumption:
1) 1D, steady state heat conduction.
2) k != f(T)
3) No Radiation Heat transfer & irregularities in the geometry
Parameters: p (perimeter); Ac(Conduction area); As (Convection area); th (thickness of fin); k(thermal conductivity);
h(convection heat transfer coefficient associated with surrounding), T∞(Ambient Temperature), Ts (Surface
temperature of object on which fins are installed); L (length of fin)

Convention: length in x-direction, breadth in z-direction & height(th) in y-direction

Using Cartesian coordinates as basis;
Energy Balance turns out into:
(𝑥) (𝑥 + 𝑑𝑥)
𝑄𝑐𝑜𝑛𝑑𝑢𝑐𝑡𝑖𝑜𝑛 = 𝑄𝑐𝑜𝑛𝑑𝑢𝑐𝑡𝑖𝑜𝑛 + 𝑄𝑐𝑜𝑛𝑣𝑒𝑐𝑡𝑖𝑜𝑛 – (1.4)
Also,
𝑄𝑐𝑜𝑛𝑣𝑒𝑐𝑡𝑖𝑜𝑛 = = ℎ. (𝑝∆𝑥). [𝑇 − 𝑇∞] – (1.5)
From eqn. (1.4) & (1.5), on rearranging the terms, we get:
(𝑥 + 𝑑𝑥) (𝑥)
(𝑄𝑐𝑜𝑛𝑑𝑢𝑐𝑡𝑖𝑜𝑛−𝑄𝑐𝑜𝑛𝑑𝑢𝑐𝑡𝑖𝑜𝑛)
0= ∆𝑥
+ ℎ. 𝑝. (𝑇 − 𝑇∞) – (1.6)
Thereby in limits of ∆𝑥 → 0; we get:
(𝑥 + 𝑑𝑥) (𝑥)
(𝑄𝑐𝑜𝑛𝑑𝑢𝑐𝑡𝑖𝑜𝑛−𝑄𝑐𝑜𝑛𝑑𝑢𝑐𝑡𝑖𝑜𝑛)
0= 𝑑𝑥
+ ℎ. 𝑝. (𝑇 − 𝑇∞) – (1.7)
𝑑𝑄𝑐𝑜𝑛𝑑𝑢𝑐𝑡𝑖𝑜𝑛
0= 𝑑𝑥
+ ℎ. 𝑝. (𝑇 − 𝑇∞) – (1.8)
Now; from Fourier’s law of conduction; we get :
𝑑 𝑑𝑇
0= 𝑑𝑥
(− 𝑘. 𝐴𝑐 𝑑𝑥
) + ℎ. 𝑝. (𝑇 − 𝑇∞) – (1.9)

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 ChEA: PMD
SimuTech Project’ 22
Mentor : Sunny K. Bhagat©
Using k!=f(T);
𝑑 𝑑𝑇 ℎ.𝑝
0= 𝑑𝑥
(𝐴𝑐 𝑑𝑥
) − 𝑘
. (𝑇 − 𝑇∞) – (1.10)
Further assuming, A c & p to be constant for a rectangular unifin model, we get:
2
𝑑𝑇 ℎ.𝑝
0= 2 − 𝑘.𝐴𝐶
. (𝑇 − 𝑇∞) – (1.11)
𝑑𝑥
Finally from eqn. (1.11), it is seen that we came across a 2nd order equation, and after which to solve the equation we
require necessary B.Cs to get profiles of Temperature as a general solution depending on a case-to-case basis.
For simplications; assume T-T∞ ⇒ θ ; θ=θ(x) since T=T(x)
2 2
𝑑𝑇 𝑑θ 𝑑𝑇 𝑑θ ℎ.𝑝
Also; 𝑑𝑥
= 𝑑𝑥
or 2 = 2 & Also assume 𝑘.𝐴𝐶
= m2 = constant
𝑑𝑥 𝑑𝑥
Further simplification of approach brings ODE into a linear homogeneous simplified ODE;
2
𝑑θ 2
2 − 𝑚 . θ = 0 – (1.12)
𝑑𝑥
Recall MTH102!! The general soln. Of these form of ODE is θ = c1.e(mx) + c2.e(-mx)
Initial Boundary Condition : @(x=0); T=Tb ⇒ θ=θb — (A)

Case A: Infinitely long fin (L → ∞)

@(x=L), T→T∞ ⇒ θ = 0 — (B)
Using (A), (B), and eqn. (1.12) we get the temperature profile for this case to be:
ℎ.𝑝
θ(𝑥) = θ𝑏. 𝑒𝑥𝑝(− 𝑚𝑥) = θ𝑏. 𝑒𝑥𝑝(− 𝑘.𝐴𝐶
𝑥) – (1.13)
Case B: Adiabatic/ Insulated fin tip [Most realistic scenarios]
𝑑𝑇 𝑑θ
@(x=L), 𝑑𝑥 = 𝑑𝑥 = 0 — (C)
Using (A), (C), and eqn. (1.12) we get the temperature profile for this case to be:
𝑐𝑜𝑠ℎ (𝑚[𝐿−𝑥])
θ(𝑥) = θ𝑏 . 𝑐𝑜𝑠ℎ (𝑚𝐿)
– (1.14)
In the above expression; there are terms that involve hyperbolic cosines function. In case you are unaware of the same,
Do Check it out! [Google is available!]

Case C: Known Temperature of fin Tip

@(x=L), T→𝑇 ; θ = θ — (D)
𝑙 𝑙

Using (A), (D), and eqn. (1.12) we get the temperature profile for this case to be:
θ
[ θ 𝑙 ]𝑠𝑖𝑛ℎ (𝑚𝑥) + 𝑠𝑖𝑛ℎ (𝑚[𝐿−𝑥])
θ(𝑥) = 𝑏

𝑠𝑖𝑛ℎ (𝑚𝐿)
– (1.15)
Case D: Convection & Radiation from fin Tip
𝑑𝑇 𝑑θ
@(x=L), − 𝑘. 𝑑𝑥 | = ℎ𝑒𝑓𝑓𝑒𝑐𝑡𝑖𝑣𝑒. (𝑇 − 𝑇∞) ⇒ − 𝑘. 𝑑𝑥 |𝑥=𝐿 = ℎ𝑒𝑓𝑓𝑒𝑐𝑡𝑖𝑣𝑒. θ𝑙— (E)
𝑥=𝐿
Using (A), (E), and eqn. (1.12) we get the temperature profile for this case to be:
ℎ𝑒𝑓𝑓𝑒𝑐𝑡𝑖𝑣𝑒
𝑐𝑜𝑠ℎ (𝑚[𝐿−𝑥]) + 𝑚𝑘
𝑠𝑖𝑛ℎ (𝑚[𝐿−𝑥])
θ(𝑥) = ℎ𝑒𝑓𝑓𝑒𝑐𝑡𝑖𝑣𝑒 – (1.16)
𝑐𝑜𝑠ℎ (𝑚𝐿) + 𝑚𝑘
𝑠𝑖𝑛ℎ (𝑚𝐿)
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 ChEA: PMD
SimuTech Project’ 22
Mentor : Sunny K. Bhagat©
Exercise 1.2.A: For each possible scenario of boundary cases, try to derive the finally computed expression of θ'𝑠?
Exercise 1.2.B: Can you figure out, where does geometry plays a role in the generation of temperature gradients formulas?
Exercise 1.2.C: If there is some wear and tear in the equipment (including fin installation), will it affect anywhere at the
temperature profile? If Yes, then How?
Exercise 1.2.D: Think and derive heat transfer rates in each of 4 boundary cases?
Exercise 1.2.E: Can you think about some automation steps till now, maybe the industry lacks somewhere? (Point it out!)
Exercise 1.2.F: Can we comment for an idealistic scenario, what would be the tradition of flux w.r.t distance from the base of
the fin. Got something amazing to conclude?
Exercise 1.2.G: What is ℎ
𝑒𝑓𝑓𝑒𝑐𝑡𝑖𝑣𝑒
?

Think!!: Generally common insights of T∞ could be encountered as limiting scenarios of Temperature, but do you know the
physical significance of this T∞? In addition, given the four scenarios of boundary cases, do you think an infinitely long fin may be
considerable in real scenarios?
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Fin Effectiveness (ϵ )
So, Great!! We are installing fins. But, how could you check that really we are in good turnout of better heat transfer by
installing fins? To check the same, here we are introducing a follow-up concept in terms of effectiveness. Effectiveness
is defined as Net heat transfer rate in a real scenario w.r.t the no-fin case.
Mathematically representing;
𝑄𝑓𝑖𝑛 𝑄𝑓𝑖𝑛
ϵ = 𝑄𝑛𝑜𝑛−𝑓𝑖𝑛
= ℎ.𝐴𝑐,𝑏.θ𝑏
– (1.17)

where,
a. Ac,b is the fin cross-sectional area at the base (i.e. Footprint of the fin, after it is detached from the object where
it was installed) [Schematic: Supplementary Part C]
b. θ is Excess Temperature at the base i.e. T b - T∞; where Tb is the same temperature whatever it is at the base.
𝑏
Carefully note the above conventions, how these parameters are defined!!
● Effectiveness compensates for added cost & complexity of the design.
Example: For an infinitely long fin case;
Qfin : ℎ. 𝑝. 𝑘. 𝐴𝑐 θ𝑏 [ Exercise 1.2.D ]
𝑄𝑓𝑖𝑛 ℎ.𝑝.𝑘.𝐴𝑐 θ𝑏 𝑘.𝑝
⇒ϵ
𝑓
= 𝑄𝑛𝑜𝑛−𝑓𝑖𝑛
= ℎ.𝐴𝑐,𝑏.θ𝑏
⇒ ℎ.𝐴𝑐

In order to increase the effectiveness of fin installation for better heat transfer, we can manipulate:
a. k to be higher
b. Dimension Ratio (P/Ac) to be higher
c. Convection heat transfer coeff. to be small.
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Exercise 1.3.A: Can you think, in the case of a Double Pipe Heat exchanger or in any general heat exchanger with fins, on
what part fins need to be installed?
Exercise 1.3.B: How does effectiveness acts as a check for modeling and cost?

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 ChEA: PMD
SimuTech Project’ 22
Mentor : Sunny K. Bhagat©
Exercise 1.3.C: What would be effective for the other 3 boundary cases i.e. Known Tip temperature, radiation and convection
modes at the tip, adiabatic fin tip.
Exercise 1.3.D: Do resistances offered by footprint (at the base of fin) and that of the fin itself affect the efficiency? If yes, then
how?
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Fin Efficiency (η𝑓)

After effectiveness, for the final check, we also look over the efficiency of the fin model designed in terms of heat
transfer rates w.r.t maximum heat transfer that particular installation (inclusive of fins) could offer [Idealistic Scenario].
Mathematically denoting;
𝑄𝑓𝑖𝑛 𝑄𝑓𝑖𝑛
η𝑓 = 𝑄𝑓,𝑚𝑎𝑥𝑖𝑚𝑢𝑚
= ℎ.𝐴𝑓.θ𝑏
– (1.18)
where,
a. Af is a total contributing area of equipment (inclusive of fin)
b. As stated max. Heat transfer occurs in ideal scenarios. Recall conditions for ideal fins in the context of
Temperature.
Example: Let’s see for an adiabatic tip;
Qf = M. tanh (mL) [Exercise 1.2.D], where M is ℎ. 𝑝. 𝑘. 𝐴𝑐 θ𝑏
𝑄𝑓𝑖𝑛 𝑀. 𝑡𝑎𝑛ℎ (𝑚𝐿) 𝑡𝑎𝑛ℎ (𝑚𝐿)
η𝑓 = 𝑄𝑓,𝑚𝑎𝑥𝑖𝑚𝑢𝑚
= ℎ.(𝑝𝐿).θ𝑏
= 𝑚𝐿

Note: Since the tip is adiabatic, it won’t be contributing to the efficiency check (hence, not that area too).

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Exercise 1.4.A: If the fin is having a non-Adiabatic tip and (width>>>>thickness), What would be rectangular fin efficiency in
that scenario? [Hint: Try to draw a schematic].
Exercise 1.4.B: Check out, What is the Basel function? [Google]
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***********

Applications using Computation and Graph-based visualizations in next module [synchronous]

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