B51GU1 - Solutions Tutorial 2

2.1 A fluid at 120oC flows through a mild steel tube (k=45W/mK), internal diameter 50mm,
external diameter 56mm, and is cooled by a fluid at 30oC flowing over the tube. The internal
and external heat transfer coefficients are 1000W/m2K and 2500W/m2K respectively.
Calculate the rate of heat loss per metre length of pipe.

Estimate the percentage change in the rate of heat transfer if:

a) fouling occurs resulting in internal and external fouling resistances
of 0.0002m2K/W and 0.0004m2K/W, respectively
b) the steel tube is replaced with a copper tube (k=410W/mK) with the same internal
diameter and a wall thickness of 2mm.

Solution

1 1 r1 r2 r
= + ln + 1
U i α i k r1 r2 α o
1 25 x 10 - 3 28 25
= + ln +
1000 45 25 28 x 2500
= (1 + 0.063 + 0.357 ) x 10 - 3 m 2 K/W
= 1.42 x 10 - 3 m 2 K/W
U = 704 W/m 2 K
Q = U i A i ∆T
A i = πDL = π x 50 x 10 - 3 x 1 = 0.157m 2
∆T = 120 − 30 = 90K
Q = 0.157 x 704 x 90 = 9951 W

With Fouling

1 1
= + r fi + r f ,o
U i′ U i
= (1.42 + 0.2 + 0.4) x 10 -3 m 2 K / W
= 2.02 x 10 -3 m 2 K / W
U = 495W / m 2 K
Q ′ = U i′ Ai ∆T
Ai = π DL = π x 50 x 10 -3 x 1 = 0.157m 2
∆T = 120 − 30 = 90 K
Q ′ = 495 x 0.157 x 90 = 6995 W

Q − Q′ 9951- 6995
x 100 = x 100 = 29.7% reduction
Q 9951
 1 1 r1 r2 r
= + ln + 1
U i α i k r1 r2α o
1 25 x 10 -3 27 25
= + ln +
1000 410 25 27 x 2500
= (1 + 0.0047 + 0.3) x 10 -3 m 2 K / W
= 1.375 x 10 -3 m 2 K / W
U = 727W / m 2 K
Q = U i Ai ∆T
Ai = π DL = π x 50 x 10 -3 x 1 = 0.157m 2
∆T = 120 − 30 = 90 K
Q = 0.157 x 727 x 90 = 10,272 W

Q′ − Q 10272 - 9951
x 100 = x 100 = 3% increase
Q 9951

2.2 A fluid at 120oC flows through a mild steel tube (k=45W/mK), internal diameter 50mm,
external diameter 56mm, and is cooled by a fluid at 30oC flowing over the tube. The internal
and external heat transfer coefficients are 10W/m2K and 25W/m2K respectively. Calculate the
rate of heat loss per metre length of pipe.

Estimate the percentage change in the rate of heat transfer if:

a) fouling occurs resulting in internal and external fouling resistances
of 0.0002m2K/W and 0.0004m2K/W, respectively
b) the steel tube is replaced with a copper tube (k=410W/mK) with the same internal
diameter and a wall thickness of 2mm.

Solution

1 1 r1 r2 r
= + ln + 1
U i α i k r1 r2α o
1 25 x 10 -3 28 25
= + ln +
10 45 25 28 x 25
= (100 + 0.063 + 35.7) x 10 -3 m 2 K / W
= 135.7 x 10 -3 m 2 K / W
U = 7.37W / m 2 K
Q = U i Ai ∆T
Ai = π DL = π x 50 x 10 -3 x 1 = 0.157m 2
∆T = 120 − 30 = 90 K
Q = 0.157 x 7.37 x 90 = 104 W

With Fouling
 1 1
= + r fi + r f ,o
U i′ U i
= (135.7 + 0.2 + 0.4) x 10 -3 m 2 K / W
= 136.3 x 10 -3 m 2 K / W
U = 7.34W / m 2 K
Q ′ = U i′ Ai ∆T
Ai = π DL = π x 50 x 10 -3 x 1 = 0.157m 2
∆T = 120 − 30 = 90 K
Q ′ = 7.34 x 0.157 x 90 = 104W

Heat transfer reduction is <0.5%

1 1 r1 r2 r
= + ln + 1
U i α i k r1 r2α o
1 25 x 10 -3 27 25
= + ln +
10 410 25 27 x 25
= (100 + 0.0047 + 37) x 10 -3 m 2 K / W
= 137 x 10 -3 m 2 K / W
U = 7.3W / m 2 K
Q = U i Ai ∆T
Ai = π DL = π x 50 x 10 -3 x 1 = 0.157m 2
∆T = 120 − 30 = 90 K
Q = 0.157 x 7.3 x 90 = 103 W

Note 1% decrease in heat transfer - the effect of reducing the external surface area outweighs
the decreased (negligible) wall resistance.

2.3 Evaluate the fin efficiency for the rectangular fins listed in the table below. Use Equation2.53
and check using Fig. 2.5.

Length/mm Thickness/mm α/(W/m2K) Material

6 0.5 20 Aluminium
6 0.5 1000 Aluminium
15 1 12 Copper
15 1 12 Aluminium
15 1 12 Carbon Steel
15 1 100 Copper
15 1 100 Aluminium
15 1 100 Carbon Steel
50 2 100 Copper
50 2 100 Aluminium
50 2 100 Carbon Steel
Table Q1
Thermal Conductivity: Copper =410W/mK
Aluminium = 200W/mK
Carbon steel = 45W/mK
 In each case, if the base temperature is 75oC and the temperature of the fluid passing over the
fin is 20oC, calculate the rate of heat transfer for one fin having axial length 50cm.

Solution

It is suggested that this problem is best approached using a simple spreadsheet - this may then
be used by the student to evaluate a wider range of fin geometries.
Note that in the calculations here it is assumed that the tip is adiabatic - if the tip is part of the
heat transfer area the calculations may be repeated with the fin length equal to length +
thickness/2.

Base Temperature 75 Deg.C

Fluid Temperature 20 Deg.C
Axial Length 0.5 m

tanh( ml ) 2α
ηfin = m= ,
ml kb

Length, l Thickness,b α Material k ml Effy Q

mm mm W/m2K W/mK W
6 0.5 20 Aluminium 200 0.12 0.995 6.57
6 0.5 1000 Aluminium 200 0.85 0.814 268.62
15 1 12 Copper 410 0.11 0.996 9.86
15 1 12 Aluminium 200 0.16 0.991 9.81
15 1 12 Carbon Steel 45 0.35 0.962 9.52
15 1 100 Copper 410 0.33 0.965 79.61
15 1 100 Aluminium 200 0.47 0.931 76.81
15 1 100 Carbon Steel 45 1.00 0.762 62.87
50 2 100 Copper 410 0.78 0.837 230.18
50 2 100 Aluminium 200 1.12 0.722 198.55
50 2 100 Carbon Steel 45 2.36 0.417 114.68

2.4 A 25mm OD tube has a surface temperature of 100oC and has air passing over it at 25oC. The
heat transfer coefficient between the tube and the air is 65W/m2K. Calculate the rate of heat
loss per meter length.

Circumferential fins made of aluminium (k=200W/mK) are then attached to the tube. The fins
are 1mm thick and have an outside diameter of 55mm. There are 200 fins per metre length of
tube. If the heat transfer coefficient remains 65W/m2K, calculate
a)the rate of heat loss from one fin
b)the rate of heat loss from 1m length of finned tube.

Solution

Heat loss/metre= α A ∆T
A=πD x 1= π x 0.025=0.0785m2
Q& = 65 x 0.0785 x (100 - 25) = 358.3W

Fin efficiency
2α 2 x 65
m= = = 25.5
kb 200 x .001

From fig 3.4

 b ⎛ (55 − 25) 1 ⎞
lc = l + =⎜ + ⎟ x 10 -3 = 15.5 x 10 -3 m
2 ⎝ 2 2⎠
ro 56
= = 2.24
ri 25
ml c = 25.5 x 15.5 x 10 -3 = 0.395
η fin ≈ 0.94

Area of fin = 2 x π x (ro2 - ri2) = 2 x π x (282-12.52) x 10-6 = 3.944 x 10-3m2

remember - fin has two sides! Corrected outer radius used - this gives approximately correct
area with heat loss from tip

Q& fin = η finα A fin ∆T = 0.94 x 65 x 3.944 x 10-3 x (100-25)= 18.1W

Area of bare tube per 1m length of finned tube =(1-200b)/1 x Atube=0.8 x 0.0785 = 0.628
&
Rate of heat loss from bare tube Q tube = α A∆T = 65 x 0.628 x 75 = 306W

Total rate of heat loss = 200 x Q& fin + Q& tube = 200 x 18.1 +306 = 3926W

2.5 The inner pipe of a double-pipe counterflow heat exchanger is a 60mm diameter, thin walled
copper tube with 16 axial copper fins (k=401W/mK) of rectangular cross section attached to
it. Each fin is 60mm high and 1mm thick. Gas flows through the annulus and water flows
inside the tube. The heat transfer coefficient on the gas side is 115W/m2K and on the water
side of the heat exchanger is 2649W/m2K.

Calculate the overall heat transfer coefficient for the heat exchanger based on the area of the
smooth tube.

Solution

For fin (assume tip adiabatic)

tanh( ml ) 2α
η fin = m= ,
ml kb

l=0.06m b=0.001m α= 115W/m2K k=401W/mK

Gives m=1.44, η fin = 0.622

−1
⎛ ⎞
UA ≡ ⎜⎜ ⎟
1 1
+ rw +
(
⎝ α i′ η fi x fin area + unfinned area ) i
( )
α o′ η fo x fin area + unfinned area ⎟⎠
o

A=Internal area (unfinned), rw=0 for thin walled copper

Consider 1m length
A = πDL = π 0.06 x1 = 0.188m 2
External finned area= 16 x 2 x 0.06 x1 = 1.92m , η fin x fin area=1.19m2
External unfinned area = A-16 x 0.001 x 1 = 0.188-0.016=0.172

−1 −1
⎛ 1 1 ⎞ ⎛ 1 1 ⎞
UA ≡ ⎜ +0+ ⎟ =⎜ + ⎟ = 119W / K
⎝ 2649 x 0.188 115(119
. + 0.172) ⎠ ⎝ 498 157 ⎠

U=UA/A=119/0.188=632W/m2K