Heat Exchangers: Fundamentals and Design Analysis

Prof. Prasanta Kumar Das

Department of Mechanical Engineering
Indian Institute of Technology, Kharagpur

Lecture – 19
Extended Surface Heat Exchangers : Some Example

Hello, for quite a few lectures we are discussing regarding Extended Surfaces. Extended
surfaces are very important that is why we are spending some time on it. We need to
know what are the different options available, we need to know using extended surfaces
what different designs various designs of heat exchanger we can have, how to estimate
the rate of heat transfer from extended surfaces, etcetera?

So, in continuation with my previous lectures, the present lecture, we like to see again
some extended surface heat exchangers. If you recall, we were doing some numerical
examples to know how to calculate the heat transfer from extended surface without
bringing in heat exchanger. Now, we slowly go into heat exchangers and how extended
surfaces are utilized in heat exchangers, how calculation can be done for extended
surface heat exchangers? So, this is what we want to do with the help of again number of
examples.

(Refer Slide Time: 01:32)

This is kind of write up I have given; almost a very brief, but very important that heat
exchanger with extended surfaces or fins, there could be a two different type of design.
One is fin plate heat exchanger. Now, fin plate heat exchanger might have number of
variations, those variations I am not discussing over here because that will be taken care
of separately.

So, there is no point, I mean one should not think that there are no variations of this
thing. So, here I want to write that variations that will be discussed later. One should not
think that plate fin heat exchanger does not have any variation.

So, what I have written variations will be discussed later, but fin tube heat exchanger,
again there are many variations and what we can do? We can classify them between two
very important categories that tubes will have separate fins, individual fins or separate
fins and tubes will have integral fin plate. So, this we will see how they are designed.
Then fin tube heat exchanger is what we will concentrate. Later on separately plate fin
heat exchanger, which are again one very important family of heat exchanger we will
take care of it.

There are primarily, they are these are primarily gas liquid heat exchangers; this fin tube
heat exchanger. Fluid, either single phase or phase change passes through the tube sides
and the gas passes over the finned surface. So, basically we will have tube and on the
tube we will have fin and inside the tube there will be passage of either liquid or gas
liquid or liquid vapor mixture and on the outer side of the tube which is fin there will be
passage of gas.

Each tube may have a number of separate fins or a number of tubes may penetrate the
integral fin plates. This I am telling time and again; so, that you have some idea and we
will have also a number of figures from there we will understand what I am telling.
Integral fin plates are parallel to each other and they produce fin passages for the
transport of gas. What I am telling? That only fin size there are passage of gas. So, this
integral fin plate they will provide the passage through which gas will pass.

So, if you recall when we have started augmentation of heat transfer, I have told that
basically the engineer has to analyze what is the overall heat transfer. If we see normal
cases there are five resistances. Let us say there are two fluid and we call them fluid 1
and fluid 2. So, convective heat transfer of fluid 1, fouling of fluid 1, then the metallic
surface, then the fouling of fluid 2 and convictive heat transfer of fluid 2; so these are the
five resistances.
One has to see which resistance is more and if there is a gas liquid heat transfer
equipment heat exchanger then one will find that gas side resistance is much more. So,
gas side resistance first we have to reduce. So, that is why fins are provided on the gas
side this I have repeated number of time. So, here again I am telling the same thing that
the on the fin side of the tube there will be passage of gas. Inside the tube there may be
fins rarely, but these are small fins, sometimes there are fins ok.

(Refer Slide Time: 06:25)

So, here we are having some fin tube heat exchanger to have some idea; you see on the
tube there are fins. So, let us see these three figures, there are tubes and on the tube there
is fin. So, here you can see the tube and fin they are integral. If you see this cross section
from the same material tube and fin they have been made. Now, this design is alright, but
here you see while making this kind of a component there will be lot of material taken
out or cut out or wasted quote unquote wasted because we have to make this slot
between the fins.

On the other hand what you can have? The tube is made up of a material and a separate
kind of a fin or fin surface you can attach on it, so, that you can find in these two designs.
So, both the designs are common, but the design which is shown in the top it has got the
advantage that it is having very less amount of material wastage ok. Whereas, the design
at the bottom it is integrally made fins and tubes the integration between the fins or fin
based and the primary surface of heat transfer that is very good.
Now, these are small pieces of tubes in a heat exchanger how it will be put one can see.
So, these kind of heat exchangers are very common in refrigeration, air conditioning and
cooling requirement; cooling application. So, one can see that a tube serpentine way it is
entering I am sorry it is starting from here and it is ending probably at the top. Fluid can
enter from here and fluid can go out through this while having a very long journey
through the tube.

While it is having a long journey through the tube, so, it will exchange heat with the
gaseous fluid which is outside the tube and to enhance the heat transfer with the gaseous
fluid outside the tube we will have fin. So, you can see the fin and these are kind of
integral fin. So, one fin that is pierced by number of one fin or one fin plate that is
pierced by a number of tubes so, this is what I have mentioned. So, in this case we are
seeing individual fins in this case, we are having a one fin with number of tubes piercing
it that is a fin plate with this let us go to the next diagram.

(Refer Slide Time: 09:15)

So, here again we can see different kind of geometry here, again we will not use a single
tube there will be number of tubes. So, each tubes, can have a number of fins, these fins
could be individual fins without getting any connection with another fin. So, this is one
kind of a design commonly used and actually what we want to do by providing fin we
have increased the rate of heat transfer. So, in that way we have increased the
compactness, but we are not satisfied with that, we want to go for more compact design.
So, then what we have done? In between the fins there is some sort of a gap we want to
we want to abolish this gap now we are having integral fin plate, which are pierced by
number of tubes. And two fin plates are parallel to each other so in between gas passes
so, that becomes the gas passage ok.

So, this is kind of a design we try to evolve from this first design a to design b. Again we
are going for design c, in the design c what we can find that these tubes has been made
flat. There are several reasons why we like to make these tube flat, one reason could be
that you see a circular body is a blub body and when we are making it flat.

So, we are reducing the form drag when a gas will pass through so, this is one variation
we can find here. Another variation you see there are fin plates, but on the fin plates there
are some sort of a surface modification which has been done. Surface modification in the
sense maybe there are some holes or (Refer Time: 11:18) or louvers. So, this will give
some sort of a agitation or good mixing of the gas stream which is passing over this fins.
So, so many things we have done.

First thing you see how this concept of compactness has increased, how; first thing there
were bare tubes, on the bare tubes we have provided number of fins. Then interfin gap
where there was no material. So, that gap we have abolished by providing integrated fin
plate. Then we have made these tubes flatten and then what we have done? On this fin
plate we have provided louvers or some sort of perforations or some sort of a surface
feature which is good for mixing.

So, by all these thing you can understand that we can reduce the size of the heat
exchanger and we can within a small volume we can have large amount of heat transfer.
That is the whole purpose and that is what I like to impress upon tube.

(Refer Slide Time: 12:33)

Let us move to the; so, here I can tell you that by this time probably we are convinced
that though in heat transfer books and I have also done the same way, that we have
analyzed a single fin that we never use a single fin. In a heat exchanger, we use a large
number of fin, we use a fin surface. So, if you recall that is why we have calculated the
surface efficiency where there are number of fins; one or two lectures before we have
done this. In this case, I am showing that there are number of fins.

So, there will be some sort of a temperature at the fin base and these are different
resistances. One resistance will be provided by the fin and another resistance will be
provided by the surface area in between the fin that unfinned surface primary surface.
So, we can make some sort of a thermal circuit like this ok. These are parallel path, heat
can flow through this heat can flow through this means heat can flow through the surface
of the fins.

So, some sort of a for understanding one can have a thermal circuit as it has been shown
over here. But another thing also I have told you that this is integral fin from the same
material fin and the base surface has been made. That means, I have to take away this
much of costly material. And sometimes we cannot permit this so, we have to separately
attach the fin.

If I separately attach the fin, obviously, there will be some sort of a resistance, thermal
resistance because I am attaching one material with another material. So, here you can
see that this contact resistance; it could be called contact resistance, contact resistance of
the fin is coming. So, ultimately again we can get a thermal circuit like this. So, all these
things are important when we are doing the design of a fin heat exchanger.

(Refer Slide Time: 14:56)

Let us go to the next, so, here I have shown different kind of arrangement. These are all
tubes and only one side of the tube has been shown. The first one is the fins are made
from the same material itself, in the second one this is the tube surface on the top of that
I have used some sort of a script which is having fins.

So, it is found around the tube; so, this is one kind of a design ok. So, generally for fins
to make the fins thinner and to make the fins very effective in heat transfer, what we
have to do? We have to use high heat transfer material, high thermal conductivity
material with high thermal conductivity. And cost of those kind of material will be large,
so what we have to do is like this that if that tube material is something else and on the
top of that we provide fin material, but now or some sort of a feature, some sort of a
arrangement where fins are there made of highly conducting material. So, then probably
our cost will be less.

So, here again this is the tube material and on to the top of that there is a sleeve which is
having fins. Here again another kind of a design so that the fins are tightly attached to the
tube material which is shown here so many different kind of designs are available. And
these are done that fining machines are available with the help of machines one can
provide the fins on the circular cylinder ok.
(Refer Slide Time: 16:49)

Now, if we go to one problem, where so far we have deal dealt with a single fin now we
like to deal with a multiple fin or surface with multiple fin. This is a problem which is
taken from the book of Dewitt and Incropera. And the problem reads the engine cylinder
of a motorcycle is constructed of this aluminum alloy and is of height 0.15 meter and
outside diameter is 50 millimeter.

Under typical operating condition the outer surface is at a is at a temperature of 500 k

and is exposed to ambient air at 300 k with a conviction coefficient of 50 watt per meter
square Kelvin. Annular fins are integrally cast with the cylinder to increase the heat
transfer to the surroundings consider five such fins five such fins, which are of thickness
t is equal to t is the fin thickness.

Sometimes delta is being used you can see for indicating the fin thickness sometimes,
small t is used for indicating the film thickness sorry fin thickness 6 millimeter length L
is equal to 20 millimeter and equally spaced. What is the increase in heat transfer due to
the use of fins? So, what are known operating condition of a finned motorcycle cylinder
and increasing heat transfer associated with using the fins that is what we have to
determine. We have to find out the increase in heat transfer by the use of fins.
(Refer Slide Time: 18:47)

If we so, you see this is this is the figure. So, this can we can as well think of it is a heat
exchanger basically, it is a heat exchanger. So, there will be some fluid inside the
cylinder and that fluid will have higher temperature. So, that temperature due to this
higher temperature the cylinder body will be heated and outside there will be another
fluid. So, that will take away this heat, so, that the temperature rise or the whatever heat
is generated that heat is dissipated through the outside fluid which is the ambient air.

So, basically then it is nothing, but a gas to gas heat exchanger, we can think of
idealizing as a gas to gas heat exchanger. I have told that primarily when there is a finned
heat exchanger inside there is a liquid and outside there is a gas. So, here we can see
outside there is a gas, but inside also there is a gas that is the combustion product of the I
C engine. So, different dimensions have been given the dimensions the total height has
been given, diameter has been given, length of the fin has been given and the fin
thickness has been given. Then the fin spacing also we can get from this so, these are the
given data of the problem.

What assumptions we can make? Steady state condition, this let me tell you all the heat
exchanger analysis which we are going to do; in this course are steady state. Transient
phenomena in a heat exchanger is also very important, there are different type of analysis
with time how the temperature changes. So, those kind of analysis are done and those
analysis are important because sometimes those transient can give rise to thermal spaces
which are not which are not allowable high thermal stress or one need to check the
thermal stress.

But here, we will present steady state analysis and the present problem is not an
exception. One dimensional radial conduction in fins so, heat will be conducted in this
direction. And then it will be convicted from the surface of the fins ok. Constant
property, properties are constant negligible variation exchange with surroundings with
surroundings there will be negligible radiation exchange; that means, entire heat transfer
is due to conviction not due to radiation.

Uniform convection coefficient over the outer surface with or without fins this is an
idealization. Number of times what I am telling that whenever we provide fins we
provide the we make a change in the surface conditions. And the convictive heat transfer
coefficient will be different, but for many of the examples and some of the practical
cases, we do not differentiate between the heat transfer coefficient change with fin or
without fin. So, this is one idealization we make and by some sort of design factor we
take care of it.

Then this curve this curve is similar because, I mean familiar because this type of curve I
have shown earlier. So, here there is a way by which you can determine the efficiency of
the radial fin or circular fin. Because, otherwise, we need to calculate basal function
which is which is, not very convenient to do here you see length of the fin has been
written as L c. And some correction can be done that if we neglect the heat transfer from
the tip; we are taking insulated tip that is not correct. So, that is why fin length can be
corrected as has been mentioned here this I have told earlier also.
(Refer Slide Time: 23:23)

So, now it is simple calculation even without my intervention you can understand, what
are the calculations? That with the fins in place the heat transfer rate is given by; so, this
is the heat transfer rate that is given by your fins. And where, the A t is the total area and
then there are certain calculations which has been done here. We have to calculate the fin
efficiency, so, the fin efficiency calculation has also been explained. And fin efficiency
for the fin efficiency calculation you have to calculate the L c or the corrected length that
has also been explained over here L c. And then the fin efficiency you are getting 95
percent fin efficiency.

So, you see, we have taken the examples and many examples we have calculated the fin
efficiency and we are really getting never we have gone below 50 percent. So, we are
really designing fin which are having high efficiency. in fact, a course the fin efficiency,
what fin efficiency will take or design will depend on the application, but rarely we go
below 70-75 percent rarely we go we generally go for higher fin efficiencies.

With the fins the total heat transfer rate is given by this is q t, all this formula you can see
and with this we can determine the total heat transfer coefficient. And the total heat
transfer coefficient is actually; in this case 690 watt, 690 watt will be the total heat
transfer from the cylinder of the internal combustion engine.

Now, this heat transfer comes from this heat transfer comes from again I like to draw
your attention, that fins are let me go back little bit. So, here what I wanted to tell you
that heat transfer will be there from the surface which is not finned or unfinned surface.
Heat transfer will be there from the two surfaces of the fins and then taking all the
surfaces all the surfaces of the fins and all the interfin surfaces which are unfinned. So,
the total heat transfer has been calculated, this is very important to understand.

And by this calculation we have got, how much we have got? We have got 690 watt. And
then if there are no fins, then only there is bare cylindrical surface and we can calculate
assuming that the heat transfer coefficient has remained same. So, assuming that we can
calculate and we get some heat transfer value as 236 watt.

So, by providing fins how much gain I have got? q t minus q w o, q total minus q without
fins that is 454 watt, so that is what we get. And then obviously, by providing fins this is
the advantage we are getting. So, basically then by this time we should be convinced that
particularly on gas side providing fins we get some advantage in heat transfer. The total
heat transfer that can be increased heat exchanger can be made compact.

But, one thing we have to keep it in mind, probably in later lecture I will touch upon that
that when we do this in many of the cases there is extra amount of pressure drop. So, our
design will be justified, if our extra pressure drop is within limit. We are getting
enhancement in heat transfer, but our extra pressure drop that is within limit.

So, this is what we will try to address in our next lecture or some lecture afterwards. So,
thank you and if you have got any queries etcetera in the forum you can place it, so, we
will try to address those queries.

Thank you once again.