Dr. Senthilmurugan S.

Department of Chemical Engineering IIT Guwahati

CL 204 Examples
Internal Forced Convection & Natural Convection

Flow of Oil in a Pipeline through a lake

Example: 1
QUESTION: Consider the flow of oil at 20 C in a 30 cm-diameter pipe at an average velocity of 2 m/s.
A 200 m long section of the horizontal pipeline passes through icy waters of lake at 0 C.
Measurements indicate that the surface temperature of the pipe is nearly 0 C. Disregarding the
thermal resistance of the pipe material, determine a) temperature of the oil when the pipe leaves the
lake b) the rate of heat transfer from the oil c) the pumping power required to overcome the pressure
losses and to maintain the flow of the oil in the pipe.
SOLUTION: Oil flows in a pipeline that passes through icy waters of a lake at
08C. The exit temperature of the oil, the rate of heat loss, and the pumping
power needed to overcome pressure losses are to be determined.
ASSUMPTIONS: 1) Steady operating conditions exist.
2) The surface temperature of the pipe is very nearly 0 C.
3) The thermal resistance of the pipe is negligible.
4) The inner surfaces of the pipeline are smooth.
5) The flow is hydro dynamically developed when the
pipeline reaches the lake.

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Flow of Oil in a Pipeline through a lake

Example: 1(contd.)
PROPERTIES: We do not know the exit temperature of the oil, and thus we cannot determine the bulk mean
temperature, which is the temperature at which the properties of oil are to be evaluated. The mean
temperature of the oil at the inlet is 20 C, and we expect this temperature to drop somewhat as a result of
heat loss to the icy waters of the lake. We evaluate the properties of the oil at the
inlet temperature, but we will repeat the calculations, if necessary, using properties at the evaluated bulk
mean temperature. At 20 C we read the properties as, from appendix 13 of Cengel Book,
= 888.1 kg/m3 ;
= 9.429*10-4 m2/s;
k = 0.145 W/m.K ;
Cp=1880 J/kg.K ;
Pr =10,863
Analysis:
(a)
The Reynolds number is
Re = VavgD/v = (2*0.3)/(9.429*10-4) = 636 (Laminar Flow)

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Flow of Oil in a Pipeline through a lake

Example: 1(contd.)

Now, the thermal entry length can be evaluated as,

Lt = 0.05 * Re * Pr * D = 0.05 * 636 * 10863 * 0.3 = 103,600 m.
which is much higher than the total length of the pipe. This is typically a case of
fluids with high prandtl number. Therfore, we assume thermally developed flow
and lets determine the Nusselts number form.

= 33.7

Note that this value of Nu number is considerably higher than the fully
developed flow of 3.66. Then,
h = k.Nu/D = (0.145 * 33.7)/0.3 = 16.3 W/m2K.

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Flow of Oil in a Pipeline through a lake

Example: 1(contd.)
Also,
As= DL = * 0.3 * 200 = 188.5 m2;

mass flow rate, m = *AS*vavg= 888*(0.25*3.14*0.3*0.3)*2 =125.6 kg/s

Now, we can determine the exit temperature as follows,
Te = Ts (Ts Ti) exp(-hA/mCp)
= 0 (0 20) exp (-16.3*188.5)/(125.6*1881)
= 19.74 C.
Thus, the mean temperature of the oil drops by a negligible amount of 0.26 C,
which is almost equal to that of the inlet temperature. Hence, there is no need
to reevaluate the properties.

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Flow of Oil in a Pipeline through a lake

Example: 1(contd.)

b)
Heat loss from the oil

Heat loss Q = h * AS * Tlm = 16.3 * 188.5 * 19.87 = 61100 W.

Where Tlm is calculated as,
Tlm = = 19.87 C.
c) PUMPING POWER REQUIREMENT
As the flow is laminar, friction factor , f = 64/NRe = 64/636 = 0.1006
And P = fLvavg2/2D = 11900 N/m2
W = (m*P)/ = (125.6*11900)/888.1 = 16.8 kW.
This is the addition power required to overcome the frictional effects.

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Heating of water by resistance heaters

Example 2
QUESTION: Water is to be heated from 15 C to 65 C as it flows through a 3-cm-internal diameter 5m-long tube (See fig). The tube is equipped with an electric resistance heater that provides uniform
heating throughout the surface of the tube. The outer surface of the heater is well insulated, so that in
steady operation all the heat generated in the heater is transferred to the water in the tube. If the
system is to provide hot water at a rate of 10 L/min, determine the power rating of the resistance heater.
Also, estimate the inner surface temperature of the tube at the exit.
SOLUTION: Water is to be heated in a tube equipped with an electric resistance heater on its surface.
The power rating of the heater and the inner surface temperature at the exit are to be determined.
ASSUMPTIONS:
1 Steady flow conditions exist.
2 The surface heat flux is uniform.
3 The inner surfaces of the tube are smooth.

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Heating of water by resistance heaters

Example 2 (Contd.)
Properties: The properties of water at the bulk mean temperature of Tb = (Ti +Te)/2 = (15 + 65)/2
= 40 C are
= 992.1 kg/m3 ; = 0.658*10-6 m2/s;
k = 0.631 W/m.K ; Cp=4179 J/kg.K ; Pr =10,863
ANALYSIS:
Cross sectional and surface areas are respectively,
Ac = (0.25*3.14*0.03*0.03) = 7.069 * 10-4 m2;
As = (3.14 * 0.03 * 5) = 0.471 m2;
Volumetric flow rate is given as 10l/min, which is 0.01 m 3/min. thus, mass flow rate is 0.01 *
992.1 = 9.921 kg/min = 0.1654 kg/s
Amount of heat supplied to increase the temperature is,
Q = m*Cp*T = 0.1654 *4179 *(65-15) = 34.6 kW.

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Heating of water by resistance heaters

Example 2 (Contd.)
The surface temperature Ts of the tube at any location can be determined from,
Ts = Tm + (q/h) ;
where Tm is the mean temperature of the fluid at any location.
Q is the heat flux and h is the heat transfer coefficient.
Heat flux,
q = Q/As = 34600/0.471 = 73.46kW/m 2.
Now, the following steps have been followed to find the heat transfer coefficient.
Average velocity = V/A c = 0.01/(7.069*10-4) = 0.236 m/s
Re = Dvavg/ = (0.236*0.03)/(0.658*10-6) = 10,760.
This is clearly turbulent flow and the entry length is,
Le = 10D = 0.3 m.
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Heating of water by resistance heaters

Example 2 (Contd.)

Assuming fully developed flow and evaluating the Nu number,

Nu = 0.023 * Re0.8 * Pr0.4 = 69.4

We also know that, Nu = hD/k, gives, h= (Nu.k)/D = 1460 W/m 2K
As we have found out the heat transfer coefficient, the surface temperature of the pipe at exit
becomes

qs
Ts Tm 65
h

73,460

115 0 C
1460

NOTE: the inner surface temperature of the tube will be 50 C higher than the mean water
temperature at the tube exit. This temperature difference of 50 C between the water and the
surface will remain constant
throughout the fully developed flow region.

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Internal Forced Convection

Example 3 (Pipe Insulation for Thermal Burn Prevention)

A 10-m-long metal pipe (kpipe= 15 W/mK) has an inner diameter of 5 cm and an outer diameter
of 6 cm is used for transporting hot saturated water vapor at a flow rate of 0.05 kg/s (See Fig.
below). The water vapor enters and exits the pipe at 350C and 290C, respectively. In order to
prevent thermal burn on individuals working in the vicinity of the pipe, the pipe is covered with a
2.25-cm thick layer of insulation (kins=0.95 W/mK) to ensure that the outer surface temperature
Ts,o is below 45C. Determine whether or not the thickness of the insulation is sufficient to
alleviate the risk of thermal burn hazards.

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Internal Forced Convection

Example 3 (Contd.)

SOLUTION: In this example, the concepts of PtD are applied in conjunction with the concepts
of internal forced convection and steady one dimensional heat conduction. The inner pipe
surface temperature Ts,i is determined using the concept of internal forced convection. Having
determined the inner surface temperature, the outer surface temperature Ts,o is determined
using one-dimensional heat conduction through the pipe wall and insulation.

Assumptions Steady operating conditions exist. 2 Radiation effects are negligible. 3

Convection effects on the outer pipe surface are negligible. 4 One dimensional heat conduction
through pipe wall and insulation. 5 The thermal conductivities of pipe wall and insulation are
constant. 6 Thermal resistance at the interface is negligible. 7 The surface temperatures are
uniform. 8 The inner surfaces of the tube are smooth.

Properties The properties of saturated water vapor at Tb=(Ti+Te)/2 = 320C are cp = 7900
J/kgK, k = 0.0836 W/mK, = 2.084x10-5 kg/ms, and Pr = 1.97 (Table A9). The thermal
conductivities of the pipe and the insulation are given to be kpipe =15 W/mK and kins=0.95
W/mK, respectively.

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Internal Forced Convection

Example 3 (Contd.)

Analysis The Reynolds number of the saturated water vapor flow in the pipe is

Therefore, the flow is turbulent and the entry lengths in this case are roughly
Lh Lt 10D = 10(0.05 m) = 0.5 m (assume fully developed turbulent flow)
The Nusselt number can be determined from the Gnielinski correlation:

Where f=(0.790 ln Re 0164)-2=0.02003

Thus the convection heat transfer coefficient for the saturated water vapor flow inside the pipe is
= 363.58 W/m2K
The inner pipe surface temperature is
= where As=

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Internal Forced Convection

Example 3 (Contd.)

The thermal resistances for the pipe wall and the insulation are

Where D0= 0.06 m + 2(0.0225m)= 0.105m

The total thermal resistance and the rate of heat transfer are

Thus, the outer surface temperature is

= 44.7C

Discussion The insulation thickness of 2.25 cm is just barely sufficient to keep the outer surface temperature
below 45C. To ensure the outer surface to be a few degrees below 45C, the insulation thickness should be
increased slightly to 2.3 cm, which would make Ts,o = 41C.

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HEAT TRANSFER IN THE TRANSITION REGION

Example 4
Ethylene glycol-distilled water mixture with a mass fraction of 0.6 and a,flow rate of 2.6 X 10 -4
m3/s flows inside a tube with an inside diameter of 0.0158 m subjected to uniform wall heat
flux. For this flow, determine the Nusselt number at the location ( x /D = 90) if the inlet
configuration of the tube is: (a) re-entrant, (b) square-edged, and (c) bell-mouth. At this
location, the local Grashof number is Gr = 51,770. The properties of ethylene glycol distilled
water mixture at the location of interest are Pr = 29.2, v=3.12 X10-6 m2/s and mb /ms = 1.77.

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HEAT TRANSFER IN THE TRANSITION REGION

Example 4 (contd.)
Solution A liquid mixture flowing in a tube is subjected to uniform wall
heat flux. The Nusselt number at a specified location is to be determined for
three different tube inlet configurations.
ASSUMPTIONS: Steady operating conditions exist.
The properties of ethylene glycol distilled water mixture at the location of interest
are Pr = 29.2, v=3.12 X10-6 m2/s and mb /ms = 1.77.
ANALYSIS For a tube with a known diameter and volume flow rate, the type of flow
regime is determined before making any decision regarding which Nusselt number
correlation to use. The Reynolds number at the specified location is
= = = 6714

= m2
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HEAT TRANSFER IN THE TRANSITION REGION

Example 4 (contd.)
Nusselt number, Nutrans, which is calculated as follows at a distance x
from the entrance:
+ {exp[(a Re)/b] + }c

8-87

where Nulam is the laminar flow Nusselt number for entrance region laminar
flows with natural convection effects,
= 1.24

8-88

and Nuturb is the turbulent flow Nusselt number with developing flow
effects,
= 0.023
8-89

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HEAT TRANSFER IN THE TRANSITION REGION

Example 4 (contd.)
TABLE 88
Constants for transition heat transfer correlation
Inlet Geometry

Re-entrant

1766

276

0.955

Square-edged

2617

207

0.950

Bell-mouth

6628

237

0.980

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HEAT TRANSFER IN THE TRANSITION REGION

Example 4 (contd.)
Therefore, the flow regime is in the transition region for all three inlet
configurations (thus use the information given in Table 89 with x /D =
90), and therefore Eq. 887 should be used with the constants a, b, c
found in Table 88. However, Nulam and Nuturb are the inputs to Eq. 887, and
they need to be evaluated first from Eqs. 888 and 889, respectively. It
should be mentioned that the correlations for Nulam and Nuturb have no inlet
dependency. From Eq. 888:
= 1.24
= 1.24 = 19.9
From Eq. 8-89

= 0.023
= 0.023 = 102.7

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HEAT TRANSFER IN THE TRANSITION REGION

Example 4 (contd.)
Then the transition Nusselt number can be determined from
+ {exp[(a Re)/b] + }c
Eq. 887,
Case 1: For re-entrant inlet:
+ {exp[(1766 6714)/276] + }-.955

= 88.2

Case 2: For square-edged inlet:

+ {exp[(2617 6714)/207] + }-0.95

= 85.3

Case 3: For bell-mouth inlet:

+ {exp[(6628 6714)/237] + }-0.98

= 21.3

Discussion It is worth mentioning that, for the re-entrant and square-edged

inlets, the flow behaves normally. For the bell-mouth inlet, the Nusselt number
is low in comparison to the other two inlets.

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Heat Loss from Hot-Water Pipes

EXAMPLE 5

A 6-m-long section of an 8-cm-diameter horizontal hot-water pipe shown in Fig below

passes through a large room whose temperature is 20 C. If the outer surface
temperature of the pipe is 70 C, determine the rate of heat loss from the pipe by
natural convection.

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Heat Loss from Hot-Water Pipes

EXAMPLE 5 (contd.)

A
horizontal hot-water pipe passes through a large room. The rate of heat loss
from the pipe by natural convection is to be determined.
Assumptions:
Steady operating conditions exist.
Air is an ideal gas.
The local atmospheric pressure is 1 atm.

Properties The properties of air at the film temperature of Tf = (Ts + T)/2 = (70 +
20)/2 = 45oC and 1 atm are (Table A15)
k = 0.02699W/m.K
= 1.750 x 10-5 m2/s

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P r = 0.7241
= 1/ Tf

Heat Loss from Hot-Water Pipes

EXAMPLE 5 (contd.)

Analysis The characteristic length in this case is the outer diameter of the pipe, L c = D = 0.08 m.
Then the Rayleigh number becomes

The natural convection Nusselt number in this case can be determined from Eq. 925 to be

= 17.39
Then,

And

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Heat Loss from Hot-Water Pipes

Example 5 (contd.)
Therefore,

the pipe loses heat to the air in the room at a rate of 442 W by natural convection.
Discussion : The pipe loses heat to the surroundings by radiation as well as by natural convection.
Assuming the outer surface of the pipe to be black (emissivity e = 1) and the inner surfaces of the
walls of the room to be at room temperature, the radiation heat transfer is determined to be (Fig. 917)

=553W
which is larger than natural convection. The emissivity of a real surface is less than 1, and thus the
radiation heat transfer for a real surface will be less. But radiation will still be significant for most
systems cooled by natural convection. Therefore, a radiation analysis should normally accompany a
natural convection analysis unless the emissivity of the surface is low.

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Cooling of a Plate in Different Orientations

Example 6

Consider a 0.6-m 3 0.6-m thin square plate in a room at 30 C. One side of the plate is
maintained at a temperature of 90 C, while the other side is insulated, as shown in Fig below.
Determine the rate of heat transfer from the plate by natural convection if the plate is (a)
vertical, (b) horizontal with hot surface facing up, and (c) horizontal with hot surface facing
down.

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Cooling of a Plate in Different Orientations

Example 6 (Contd.)

Assumptions 1) Steady operating condition exist. 2) Air is an ideal gas. 3) The

local atmospheric pressure is 1 atm.
The film temperature Tf = (Ts + Ta)/ 2 = (90+30)/ 2 = 60C
Properties of air at film temperature and 1 atm
k = 0.02808 W/mK Pr = 0.7202 , v = 1.896 x 10-5 m2/s ,
= 1/ Tf = 1/ 333K
The characterstics length is height of plate , L= 0.6 m. The Rayleigh number
RaL = g (Ts-Ta)L3 Pr = (9.81)(1/333)(90-30)(0.6)3 (0.7202)
v2
(1.896 x 10-5 )2
= 7.649 x 10 8
The natural convection Nusselt number can be determined by
a)

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Cooling of a Plate in Different Orientations

Example 6 (Contd.)
Nu = { 0.825 +0.387 RaL1/6} 2 = 113.3
[1+ (0.429Pr)9/16 ]8/27
h = k Nu = (0.02808)(113.3) = 5.302 W/m2K
L
0.6
q = hAs(Ts-Ta) = (5.302) (0.36) (90-30) = 115W
b) Horizontal with hot surface facing up. The characteristic length and the Rayleigh number
in this case are
Lc = As/p = L2/4L = L/4 = 0.6/4 = 0.15 m
RaL = g (Ts-Ta)Lc3 Pr = (9.81)(1/333)(90-30)(0.15)3 (0.7202)
v2
(1.896 x 10-5 )2
= 1.195 x 107

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Cooling of a Plate in Different Orientations

Example 6 (Contd.)

The natural convection nusselt number can be determined by

Nu = 0.54RaL 1/4 = 0.54 (1.195 x107)1/4 = 31.75
h = kNu/Lc = (0.02808)(31.75)/0.15 = 5.944 W/m 2/K
q = h As (Ts-Ta) = (5.944) (0.36) (90-30) = 128 W
c) Horizontal with hot surface facing down. The characteristic length
and the Rayleigh number in this case are the same as those determined
in (b).But the natural convection Nusselt number is to be determined
Nu = 0.27 RaL = 0.27 (1.195 x107)1/4 = 15.87
h = kNu/Lc = (0.02808)(15.87)/0.15 = 2.971 W/m 2/K
q = h As (Ts - Ta) = (2.971) (0.36) (90-30) = 64.2 W
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Cooling of a Plate in Different Orientations

Example 6 (Contd.)

Note that the natural convection heat transfer is the lowest in the case of the
hot surface facing down. This is not surprising, since the hot air is trapped under
the plate in this case and cannot get away from the plate easily. As a result, the
cooler air in the vicinity of the plate will have difficulty reaching the plate,
which results in a reduced rate of heat transfer
Discussion The plate will lose heat to the surroundings by radiation as well as
by natural convection. Assuming the surface of the plate to be black (emissivity
=1) and the inner surfaces of the walls of the room to be at room temperature,
the radiation heat transfer in this case is determined to be
q rad = 4 (Ts4 Ta 4) = (1) (5.67 x 10-8)4 (3634-3034) = 182 W
This value is larger than natural convection heat transfer for each case , so
radiation also need to be considered in surfaces cooled by natural convection .

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