Heat Exchangers: Fundamentals and Design Analysis

Prof. Prashanta Kumar Das

Department of Mechanical Engineering
Indian Institute of Technology, Kharagpur

Lecture – 17
Extended Surface Heat Transfer

Welcome back. If you recall we were discussing regarding augmentation of heat transfer;
and why we have discussed augmentation, because we wanted to have very efficient heat
exchangers. And, in technical term what is known as compact heat exchanger, at least
some of the compact heat exchanger we wanted to discuss.

Now, as I have shown you earlier that there are many techniques; many techniques or
augmentation of heat transfer. I have not shown again I let me tell you I have not shown
an exhaustive list. It is not possible because there are many techniques and probably in a
course like this where our main focus is heat exchanger we cannot discuss much detail in
much detail regarding the augmentation techniques, though they are very interesting and
as thermal engineer should know them.

Now, one of the augmentation technique is the use of extended surface or as technically
they are known fins. And using fins there are many heat exchangers which have very
superior performance. So, we are going to spend some time on fins. You have studied
about fins in heat transfer in your heat transfer course which is a very fundamental topic
in any undergraduate heat transfer course and probably some of you have revisited this
topic in some post graduate course. So, assuming that you have got some background or
you can pick up that background from a standard book of heat exchanger. We will go
only telling the critical points of this topic.

So, analysis of extended surface heat transfer this is what we are focusing on.
(Refer Slide Time: 02:14)

Fins or extended surfaces are appendages attached to the primary heat transfer surface.
So, there will be a primary heat transfer surface, we are not satisfied with the heat
transfer performance, we want to improve the heat transfer performance of this primary
surface then the easiest thing we like to do is to attach fin to it. Fin is a conductive
convictive surface.

So, initially the primary surface we had it use I mean it had heat transfer by conviction,
now we are providing things on it, still it will have heat transfer by conviction, but we
are giving now some extra area to the primary surface. The extra area will not be as
effective as the main surface of the primary; sorry as the primary surface area, but in any
case this extra area will enhance the rate of heat transfer. So, this is the whole game.

Now, if we see the attribute of extended surface or fin which is a conductive convective
surface I will explain this term. So, this is a passive device no auxiliary power is required
suitable for single phase convection, phase change heat transfer a phase change heat
transfer and radiation. Even in some even in some phase change storage system, these
fins are used energy storage system.

Then, extensive design variation can be used for planar or curved surface, can be used
inside some sort of a convict or outside the convict. It can be used as I have told that it
can be used for single phase it can be used for both liquid and gas and liquid gas mixture.
Then we can use it in a very small heat exchanger we can use it fin heat exchanger
should be very very large. So, that is one thing that is another feature and may increase
by the fin design definitely we are increasing the surface area, but by our innovative
design we can sometime increase the heat transfer coefficient also. Sometimes some
other thing like by some sort of a good design in condensation we can promote the
drainage of condensate field which is very important.

Then, as it is a passive device so, it will have the features of passive device; that means it
is highly reliable low maintenance all these things are there.

(Refer Slide Time: 05:17)

Some of the common fins I have shown. So, let me let me let me try to explain certain
things over here. And so, this is the primary surface let us say this is the primary surface,
this is the primary surface and on this primary surface I have added some sort of a
secondary surface or extended surface this is our fin. So, the first one is a longitudinal
fin. So, as I have earlier told that it is a conductive convictive system. So, let us
understand why I have told this.

So, what now initially I had a surface area or surface like this, like this I had a surface I
had a surface like this. So, this was my surface. So, this was my surface. Now, what is
happening with this fin my surface area is like this, this much surface area I have got,
this much surface area I have got, this much surface area I have got, and at the back of
the fin then again the same amount of surface area we have got. So, by providing a single
fin I can see how much extra surface area I could provide to my design.
So, this is one of the design, but in industry there are many design where the heat transfer
surface is carved. Let us say the fluid is flowing through the through a tube and the fluid
is to be cooled or heat heated by providing some sort of gas flow over the outside of the
tube. So, here we can provide this kind of fins on the tube these are called longitudinal
fins on the tube, ok.

Similarly, for a tube we can provide so, this kind of radial fin. Similarly, for a planar
surface we can provide this kind of cylinders solid cylinders which are also fins and they
are called pin fins, they look like a pin. So, they are like pin fins; again, I the draw your
attention that in case of planar fin only one fin has been shown. In case of radial fin or
annular fin or sometimes it is called circular fin. In case of planar fin only one fin has
been shown, that is this one. In case of radial fin which is also called circular fin or
annular fin only one fin has been shown in case of pin fin only one fin has been shown.

But, rarely any practical application a single fin is used. So, basically we used a fin
surface as we have shown in this case, but in all the other cases for the clarity for
understanding we have shown only one typical fin, in actual practice there will be many
number of fins on the surface. So, with this let us move to our next this one.

(Refer Slide Time: 09:09)

Next slide, limitation of fin heat exchangers, first thing is cost. So, obviously, when we
are attaching fins; so, it will improve the cost. How it will improve the cost because the
fin material has to be a good conductor of heat. So, obviously, we cannot use any
material, we have to use some costly mat material and then weight and volume of the
heat exchanger that will definitely increase. Most of the cases we will have an increase in
pumping power and then there could be fouling.

Now, weight and volume obviously, it is not desirable in any system increase in weight
and volume, but particularly if it is a mobile system let us say for an aircraft we are
trying to have a heat exchanger with fins we have to be careful. For a racing car, for an
automobile we want to have automobile moving with a high velocity you want to have a
heat exchanger very efficient by putting number of fins we have to be careful. Because,
in all these cases this addition of fins not only increases the volume, but also increases
the weight of the mobile system moving system and which is more traction power. So,
we have to be careful.

Dimensions of the fin in the longitudinal direction that is in a direction normal to the
primary surface or base surface is much more compared to the other dimension. So,
many of the cases in the analysis of fin we can take the assumption of one dimensional
heat conduction. So, this is very important that many of the cases our fin analysis is done
based on the assumption of one dimensional heat conduction.

So, with this background let us go proceed further.

(Refer Slide Time: 11:09)

So, you see resources are not infinite, unfortunately. Particularly, engineering resources
are not infinite. So, suppose I want to improve the performance of a heat exchanger we
are not satisfied I am not satisfied with the performance of a particular heat exchanger,
then I have got limited resources. So, I should try to do it that I get the best return of my
investment.

So, first I have to decide that where I have to go for augmentation. What I am telling
please let me explain it. It is like this, that we know that in a heat exchanger there could
be many heat transfer surfaces, but a typical heat transfer surface will have two fluids on
either I mean one fluid on either side. So, one there will be a surface on the surface there
will be one fluid. Or rather let me put it in this way that two fluids are separated by some
sort of a solid valve. So, one surface of the solid valve is contacted by one fluid and
another surface of the solid valve is contacted by fluid.

Now, the augmentation or enhancement particularly, if we think of passive enhancement

we can provide on either side of the solid surface. We have to at this point. We have to
take a decision on which side we are going to provide the augmentation or on both the
side we are going to provide the augmentation. Now, if we have got limited resources as
I have told then we have to decide at least that to start with which side should be our
target for providing the augmentation.

For this what we have to do we have to think of the thermal resistances in the path of
fluid in the path of flow of heat. Heat is getting transferred from one solid one moving
fluid to another moving fluid. There are several resistance for fluid 1 there is a resistance,
the fluid 1 side there could be some fouling for that there is a resistance. In the solid
valve there is a resistance in fluid 2 side there could be fouling there is a resistance and
in the fluid 2 there is a resistance I think these have these have been already told.

So, we can proceed. So, bringing in overall heat transfer coefficient bringing in overall
heat transfer coefficient so, here the overall heat transfer coefficient and area I have plot
in. So, we have got five resistances the convective heat transfer on the fluid one side this
is one, the fouling resistance on the fluid one side I have put in the form of convective
heat transfer coefficient, the resistance in the solid valve this is another, then the fouling
on the fluid 2 side that is another and then resistance in fluid 2 that is another.
So, in general most of the cases we will have this five resistance. Now, we can have
some sort of a because it is very difficult to separate them that resistance in the
convection in a particular fluid and just beside it is the resistance due to file due to
fouling in that particular fluid we can club them together. Suppose, the situation is such
that for fluid one side these two resistances summation of these two resistances are much
more compared to the summation of other resistances, then we can take a clear cut
decision that the augmentation is to be done on the fluid one side.

So, this is how we have to decide, there are some guidelines very simple guidelines
because it comes from our day to day experience and these guidelines are of course,
more or less commonly fold commonly followed, but sometimes it needs some sort of a
change. It is like this that if there is a gas liquid heat exchanger generally gas side
resistances are more. So, if we are going as we have discussed that that fin is one kind of
a technique which we can adopt. So, if we are going to provide fins so, we have to
provide first on the gas side.

In many cases on the liquid side we need not provide fin, sometimes we provide small
fins etcetera for enhancing the heat transfer if the rate of heat transfer or coefficient of
heat transfer. But, if it is gas liquid that then almost in hundred percent cases the decision
is taken to enhance the rate of heat transfer in the gas side by providing fins, ok. If it is a
gas to gas heat exchanger, then of course many a times we provide fins on both side of
the surf solid surface on both the fluid side we provide fins. So, with this small kind of
information small piece of information we can proceed for the next slide.

We can proceed for the next slide.

(Refer Slide Time: 18:05)

So, here I have shown a longitudinal fin with constant thickness. So, let me again try to
show a few things. So, sorry this is your primary surface this is your primary surface. On
the primary surface I have put some sort of a longitudinal fin you can see that the cross
section of this fin is constant; that means, the thickness of the fin is constant. So, there
are two areas which are important. One area we can think of; let us say we can think of
this area, this is one area. So, what is happening, the base the primary surface is hot. So,
from there heat transfer is taking place and the heat transfer is taking place to this area.
So, this is basically the cross sectional area which is taking part in your conduction and
let us clean.

So, then we can see one fluid is flowing over the fin, backside of the fin also fluid is
flowing, over the base surface or primary surface also fluid is flowing. So, it is like this
that fluid is flowing on the on the on this surface fluid is flowing. So, let us use this. So,
on this surface fluid is flowing, here I have shown fluid is flowing on this fluid is
flowing. So, fluid is flowing and due to that there will be some sort of a convection. So,
that is why I have told that fin is a conductive convictive system and the length of the fin
that is L the thickness of the fin is x sorry t in this direction we have taken x and t x is the
temperature at a distance x. Now, we have to understand or appreciate one thing that heat
transfer is taking place; I have shown the area through which heat conduction is taking
place there is another area that is the surface area of the fin from there convection is
taking place.
So, conduction is taking place through the cross sectional area convection is taking place
through the surface area that is one thing. Another thing that if we assume that the fin is
fin is very large; the fin is very large along this direction and along this direction. So, one
can one need not consider a temperature variation along this direction I have told that
this fin is very long in this direction compared to it is thickness. So, along this direction
there will be temperature variation, but along this direction there will not be any
temperature variation. So, basically this direction no temperature variation this direction
no temperature variation, this direction no temperature variation, only temperature
variation is along the longitudinal direction. So, this is what we do in fin and this
probably is known to you known to all of you from your heat transfer course.

(Refer Slide Time: 22:23)

Analysis of the convective fin: convective fin means the heat transfer from the surface of
the fin is taking place by convection based on 1-D heat conduction. I will not spend
much time, because these are all the staff of heat transfer, I will not explain also because
I expect you people to go back to a heat transfer book if you cannot figure it out. This is
some minimum requirement for this particular course, so for the fin which I have shown.
So, one can write this kind of an equation. The first equation which has been written it is
assumed that the surface area changes along x direction or longitudinal direction cross
sectionality also changes.
Now, if we take some sort of a longitudinal fin with constant thickness we can get this,
then we replace t x minus t infinity which is the fluid temperature by some theta we get
this kind of a formulation.

(Refer Slide Time: 23:44)

And, then we um if we impose the boundary condition the boundary condition common
boundary condition is that at the fin base. Where the fin is attached to the primary
surface it is having a known temperature and on the t that is the other end of the fin that
is insulated with these boundary condition we can get a temperature difference sorry
temperature distribution along the length of the fin.

And, flow of heat through the fin which is coming from the base. So, at the base what is
the heat flow that is the again heat transfer by the fin to the surrounding fluid. So, that
will be q f. With this if we go for the next slide.
(Refer Slide Time: 24:35)

So, we have got the heat transfer and we have got the temperature distribution if you
recall you will find that probably the most common type of fin we have taken which is a
longitudinal fin, either it could be of rectangular cross section or it could be some sort of
a pin fin. So, if you aware our cross section is constant. So, in then we are getting a very
complex equation or rather complex equation not very complex, but complex equation.

But, if the fin geometry is more complex all these simplicities are not there, we can
imagine that the equation will not be very easy to remember or easy to handle that is the
one point. Another point, how I know that whether the fin I have designed, that is, good
or that is not so good? So, here we introduce some figure of merit which will give us the
goodness of my fin design and at the same time we will explain that it will make my life
simple that when I have to estimate how much heat transfer is there from the fin.

So, it is like this if we go back to the slide ppt. So, we define fin effectiveness again these
are all staff of heat transfer and then what we do we get it like this that effectiveness is
heat transfer from the fin, heat transfer to the fin based without the fin. So, this is how we
get or in terms of thermal resistance we can get. So, this is one way of doing it.
(Refer Slide Time: 26:31)

There is another figure of merit that is fin efficiency that is heat transfer through the fin
and maximum possible heat transfer through the fin. How we can get maximum possible
heat transfer? If we assume that fin is made of a material which is some sort of a highly
conductive material, there is no temperature drop across the fin. So, we get that and then
this is a very important this is a very important kind of information and we get the fin
efficiency eta f which is given by tanh ml by ml, tan hyperbolic ml by ml.

I am not going back, but there is m which has been defined while I have shown in the
previous slide, it is some sort of a design parameter thermo geometric parameter of the
fin which is very important for the fin design and l is the length of the fin, ok. So, with
this we get the efficiency of the fin. So, we can tell by adding the fin how much is the
gain we can compare between two fin design, but at the same time once we know the fin
efficiency what we can do the fin area can be multiplied with this fin efficiency.

So, from the name efficiency it will be clear that what we are getting is less than 100
percent. So, the fin area will be multiplied by this; that means, the entire area of fin or
rather let me put it like this, the fin area is not as efficient as transferring not as efficient
in transferring heat as the base area. If we multiply it with some sort of a factor which is
less than 100 percent or less than 1, then the area of which we are getting that is equally
efficient as the base area.
Base area heat transfer how can we get? H a delta t, we do not have any fin equation
etcetera. Here, somehow somebody is supplying me with the fin efficiency the fin area I
will multiply with the efficiency and then we will have our h a fin into efficiency into
delta t that will be the heat transfer. So, this is the advantage of introducing efficiency.

I have just explained it in nutshell knowing that that this has been done in your or this
you have done this you have done in your earlier class.

(Refer Slide Time: 29:43)

So, sorry let me get it cleared. So, here I have shown how the fin efficiency will vary
with some sort of a some sort of a some sort of a geometrical and thermo geometrical
parameter for different kind of fins only longitudinal fin if a analysis I have shown, but
other fins can be analyzed. Here only one thing is there instead of L the length of the fin
the some sort of Lc has been used. Lc is in the corrected length for the assumption of the
insulated tip.

What we have assumed the tip is insulated, but the tip is not actually insulated. So, there
will be certain amount of heat transfer. So, actual length of the fin can be corrected with
some sort of a correction. So, which is given here and that is what is used in many of the
many of the many of the analysis.
(Refer Slide Time: 30:53)

So, circular fin; so here also we will get the expression of theta which is the non
dimensional term temperature in terms of modified Bessel function of zero order and
first order then efficiency we also get. But, you can see the how the efficiency formula
has become complex that is what I was going to tell that sometimes the fin analysis is
very complex for a circular fin which I have shown earlier. So, the i m analysis becomes
very complex and then in this case the efficiency generally we determine with the help of
a chart or with the help of a graph like this and here I have shown how it can be one can
use this, ok.

So, these two fins what I have shown that the longitudinal fin on a plane surface or
circular fin over a tube surface are very important and they will be very commonly used
very extensively used in our heat exchanger design. So, some of these things we will
discuss some of these thing we will use in our further classes. So, this provide some sort
of a base knowledge for you and why I have included, I could have told only that these
are used in our heat exchanger design. Because, this is a heat transfer staff which is not
connected directly or not to be included mandatorily in a course on heat exchanger, but
we have given this for it is importance in the course.
(Refer Slide Time: 32:36)

Now, the last one I like to tell that on a surface there will be number of fins. So, as we
have defined fin efficiency there could be surface efficiency also. There could be surface
efficiency and the surface efficiency is sometimes called the overall surface efficiency is
given like this. Why overall surface efficiency? Because in a fin surface from the fin heat
transfer is there and also where fin is not there heat transfer is there from the base surface
or primary surface.

So, following the analysis which I have given which is very simple one can define the
overall surface efficiency by this formula and here actually you need to know what is the
number of fins the capital N the fin area for um fin how much is the area, you need to
know the fin efficiency and you need to know the total area. So, with that we can have
some sort of a surface efficiency. So, in a heat exchanger as we are not using a single fin
we need to have the basic information of fin efficiency, but from there we need to
calculate the surface efficiency which we need to use in the fin heat exchanger design.

With this, I like to end my end my lecture and I thank you all for attending this. If there
is any queries or confusion, we can discuss that if you indicate it in the forum. But what I
like to tell that knowing the basic heat transfer or remembering the recalling the basic
heat transfer connecting it with what we are teaching is very important and I like you to
do that.

Thank you.