CHAPTER Five

5. CONVECTION HEAT
TRANSFER

1
 5.1 INTRODUCTION
 Convection is one of the three basic mechanisms of heat
transfer. It is a heat transfer that takes place between moving
fluid and solid surface.
 Like conduction heat transfer, convection heat transfer
requires material medium.
 Heat transfer by convection combines heat transfer by
conduction and bulk flow of fluid.
 Convection heat transfer depends on several parameters like:
 Fluid properties
 Dynamic viscosity, μ.

 Thermal conductivity, k.

 Density, ρ.

 Specific heat capacity, cp.

2
  Fluid velocity, v.
 Geometry of solid surface.
 Roughness of solid surface.
 Type of fluid flow (turbulent or laminar).
 The dependence of convection heat transfer on
so many variables makes it very complex and it
is usually determined experimentally.
 The convection heat transfer rate is given by
Newton’s law of cooling,
.
Q conv.  hA(Ts  T ) (5.1)
Where
h=convection heat transfer coefficient,
A=heat transfer surface area,
Ts=surface temperature,
T∞=fluid temperature far away from surface. 3
Non dimensional convection coefficient
 The convection heat transfer coefficient, h, is non
dimensionalized to obtain the Nusselt number, Nu.
h
Nu 
k (5.2)
Where k =thermal conductivity,
=characteristic length.
 The Nusselt number can also be given as the ratio of
convection heat transfer rate to conduction heat
transfer rate.
Convection heat transfer rate
Nu 
Conduction heat transfer rate
.
Q conv.
Nu  . (5.3)
Q cond . 4
 5.2 VELOCITY BOUNDARY LAYER
 The region of flow that develops from the leading
edge of the plate in which the effects of viscosity are
observed is called the boundary layer.
τ Shear stress
 is the value of y for which
u  0.99u

Fig. 5.1 Velocity boundary layer development over flat plate 5

 For external flows the velocity boundary layer concept
provides the basis for determining the local friction
coefficient.
s
Cf  (5.4)
1 2
u
2
 Where the surface shear stress for Newtonian fluid is
obtained from the relation,

u (5.5)
s  
y y 0

 μ is called the dynamic viscosity

 The drag or friction force over the surface is
determined by
u2
FD  C f A (5.6)
2
6
 5.3 THERMAL BOUNDARY LAYER
t is the value of y for which the
ratio
(Ts  T ) /(Ts  T )  0.99

Fig. 5.2 Thermal boundary layer development over isothermal flat plate

7
 At any distance x from the leading edge, the local heat flux may be
obtained by applying Fourier’s law to the fluid at y= 0. That is,
T (5.7)
qs   k f
y y 0
 By combining equation (5.7) with Newton’s law of cooling we then
obtain
T
kf
y y 0
h  (5.8)
Ts  T

 The relative thickness of the velocity and thermal boundary layers is

described by Prandtl number,

Momentum diffusivity  CP

Pr    (5.9)
Heat diffusivity  k
 The hydrodynamic and thermal boundary layers are related in terms of
Prandtl number as
t 1
 Pr 1
 1.026 (5.10)
8
 5.3THERMAL BOUNDARY LAYER ……….

Fig. 5.3 Relative thickness of the velocity and thermal boundary layers

9
 5.4 LAMINAR AND TURBULENT FLOW
Laminar flow: A smooth, streamline type of viscous flow
in which the fluid behaves as a system of orderly layers,
with no eddies or irregular fluctuations.
Turbulent flow: A form of irregular viscous flow in
which the velocity and pressure of the fluid fluctuates at
random in both time and space.
 The relative shapes for the velocity profiles in laminar and
turbulent flow are indicated in Figure 5.4.
 The laminar profile is approximately parabolic, while the
turbulent profile has a portion near the wall that is very
nearly linear.
 This linear portion is said to be due to a laminar sub layer
that hugs the surface very closely.
10
Fig.5.4 Laminar, transition and turbulent flow regions

11
 Initially, the boundary-layer development is
laminar, but at some critical distance from
the leading edge, depending on the flow field
and fluid properties, small disturbances in the
flow begin to become amplified, and a transition
process takes place until the flow becomes
turbulent.
 The turbulent-flow region may be pictured as a
random churning action with chunks of fluid
moving to and fro in all directions.

12
 The location where the flow turns to turbulent is
determined by a dimensionless grouping of variables
called the Reynolds number.
Inertia forces u (5.11)
Re  
Vicous forces 
Where; u∞=free stream velocity
=characteristic length of the geometry
/=kinematic velocity of the fluid
 The critical Reynolds number at which flow turns to
turbulent is about 5x105 for most analytical purposes,
but in critical value in a practical situation is strongly
dependent on the surface-roughness conditions and
the “turbulence level” of the free stream.
13
 5.5 FLOW OVER FLAT PLATES
• The friction and heat transfer coefficients for a flat plate can
be determined by solving the conservation of mass,
momentum and energy equations.
• The average Nusselt number can be expressed as

hL (5.12)
Nu   C Re mL Pr n
k

Where C, m and n are constants and L is length of the plate.

• Generally, properties of the fluid vary with temperature.
• To make the heat transfer analysis simple, properties are
evaluated at film temperature given by
Ts  T
Tf  (5.13)
2 14
• In heat transfer analysis, we are usually interested in the
heat transfer and drag force on the entire surface of the
plate which are determined using the average heat
transfer and friction coefficients.
• The local and average Nusselt number and friction
coefficient are determined for laminar and turbulent flows
separately,
Laminar flow
 The boundary layer thickness
5x (5.14)
  1
Re x 2
 Local friction coefficient

x 0.664
C f ,x   (5.15)
1 / 2 u Re 12
2
x
15
 Combining equations (5.10) and (5.14), the thermal
boundary layer thickness is given by

1 5x
t   1
Pr  (5.16)
1.026 1.026(Re1x/ 2 )(Pr)
 Local Nusselt number

hx x 1 1
Nu x   0.332 Re x Pr 3 ( pr  0.6)
2
(5.17)
k

 Average friction coefficient

1.328 (5.18)
Cf  1
Re L 2
16
 Average Nusselt number

hL 1 1 (5.19)
Nu   0.664 Re L Pr 3
2 ( pr  0.6)
k
 The critical Reynolds number

u xCr
Re Cr   5  105


17
Turbulent flow
 Local friction coefficient
C f ,x 
0.0592
1
5 10 5
 Re x  107  (5.20)
Re x 5

 Local Nusselt number

hx x 1  0.6  pr  60 
  (5.21)
4
Nu x   0.0296Re x 5 Pr 3  5 105  Re  107 
k  x 

 Average friction coefficient

Cf 
0.074
1
5 10 5
 Re L  107  (5.22)
Re L5

 Average Nusselt number

hL 1  0.6  pr  60 
 
4
Nu   0.037 Re L 5 Pr 3  5 105  Re  107  (5.23)
k  L 
18
For combined laminar and turbulent flow
Cf 
0.074 1742
1
 5 105
 Re L  107  (5.24)
Re 5 Re L
L

Nu 
hL
 4
 1
 0.037 Re L 5 871 Pr 3
 0.6  pr  60

 5  105  Re  107



(5.25)
k  L 

 The heat transfer rate is obtained from

. (5.26)
Q conv.  hA(Ts  T )

Where h
 Nu k
L

 The drag force is calculated as

u2 (5.27)
FD  C f A
2
19
 Example 5.1
1. An electric air heater consists of a horizontal array
of thin metal strips that are each 10mm long in the
direction of an airstream that is in parallel flows
over the top of the strips. Each strip is 0.2m wide,
and 25 strips are arranged side by side, forming a
continuous and smooth surface over which the air
flows at 2m/s. During operation each strip is
maintained at 5000C and the air is at 250C.
a. What is the rate of convection heat transfer from
the first strip? The fifth strip? The tenth strip? All
the strips?
b. For air velocities at 3, 5, and 10 m/s, determine
the convection heat rates for all the locations of
part (a). Represent your results in tabular or bar
graph form.
20
Solution

Ts  T
Tf 
2

21


 43.54  106
xc  5  105  5  105  10.9m
u 2

Q1  h1 L  wTs  T 
.

k 1 1
h1  0.664 Re x 2 Pr 3
L

.
Q1  51.1w 22
 For the fifth strip,
. .
Q5  Q0  5  Q 0  4
Q5  h0  5 5L  wTs  T   h0  4 4L  wTs  T 
.

k 1 1
h05  0.664 Re x 0.05 Pr 3  24.1w / m 2 K and
2
5L
k 1 1
h0 4  0.664 Re x 0.04 Pr 3  26.9w / m 2 K
2
4L
.
 Q 5  12.2w
 In similar manner for the tenth strip and entire 25 strips,

Q10  h0 10 10L  wTs  T   h0 9 9L  wTs  T   8.3w

.

Q 0  25  h0  25 L  wTs  T   255.3w
.

23
b)
velocity, heat transfer rate, w
m/s first strip fifth strip tenth strip entire strip
2 51.08 12.06 8.29 255.39
5 80.76 19.06 13.11 403.80
10 114.20 26.96 18.53 571.06

24
5.6 FLOW ACROSS CYLINDERS AND SPHERES

 The average Nusselt number for flow over a

cylinder is given empirically as proposed by
Churchill and Bernstein:
4

hD
1
0.62 Re Pr 2
1
3   Re  5
8  5

Nu   0.3  1     (5.28)
    28200 
1
k  0.4 2
3
4

1  Pr 

 Equation (5.27) is applicable for conditions where

[Link] > 0.2. The fluid properties are evaluated at
film temperature .
Ts  T
Tf 
2 25
 The average Nusselt number for flow over a cylinder
can be expressed in compact form as

hD 1
Nu   C Re Pr 3
m
(5.29)
k

Where the constants C and m are obtained from

table 5.1.
 Heat transfer to or from a bank (or bundle) of tubes
in cross flow is relevant to numerous industrial
applications, such as steam generation in a boiler or
air cooling in the coil of an air conditioner.

26
Table 5.1 Constants used in equation (5.29)

27
The tube rows of a bank are either staggered or aligned in the
direction of the fluid velocity V

Fig. 5.5 Tube bank in cross flow

28
Fig. 5.6 Aligned and staggered tube arrangement
29
 For airflow across tube bundles composed of 10 or
more rows (NL10), the average Nusselt number can be
obtained by the Grimison correlation,
 N L  10 
hD   (5.30)
Nu   C1 Re mD ,max  2000  Re D ,max  40,000
k
Pr  0.7 

 The constants C1 and m are obtained from table 3.2.

 The maximum Reynolds number is given by
(5.31)
Vmax D
Re D ,max 

30
 For the aligned arrangement the maximum velocity, Vmax
occurs at the transverse plane A1 of Fig. 3.6a and is given for
an incompressible fluid as
ST
Vmax  V (5.32)
ST  D

 For the staggered configuration, the maximum velocity may

occur at either the transverse plane A1 or the diagonal plane
A2 . It will occur at A2 if the rows are spaced such that
ST  D
2( S D  D)  ( ST  D) or S D 
2

Where SD is given by 1
 2  ST   2 2

S D  S L    
  2   31
 And ST
Vmax  V
2S D  D (5.33)
 If SD>(ST+D)/2, the maximum velocity occurs at A1 and
is given by equation (5.32).
 For flow of fluids other than air equation (5.29) is
modified by inserting 1.13Pr1/3.
 N L  10 
hD 1   (5.34)
Nu   1.13C1 Re mD ,max Pr 3  2000  Re D , max  40, 000
k
Pr  0.7 

 All the properties in these equations are evaluated at

film temperature. If NL<10 a correction factor given in
table 5.3 is used as

Nu  C2 Nu N 10
N L 10
L (5.35)
32
Table 5.2 Constants used in equations (5.30) and (5.31)

33
Table 5.3 Constant C2 used in equation (5.35)

34
 The heat transfer rate could be more predicted by using the
log mean temperature difference instead of using T=Ts-T∞.
Tlm 
Ts  Ti   Ts  To  (5.36)
lnTs  Ti  / Ts  To 
 Where Ti and To are temperatures of the fluid as it enters and leaves
the bank, respectively.
 The outlet temperature, which is needed to determine Tlm
may be estimated from
Ts  To  DNh  (5.37)
 exp  
Ts  Ti  VN T ST cP 
Where N is the total number of tubes in the bank , NT is the number
of tubes in the transverse plane and V is the speed at inlet.

35
 Once Tlm is known, the heat transfer rate may be
computed from
(5.38)
Q  N hDLTlm 
.

 For flows over a sphere, the average Nusselt number

can be obtained by the Whitaker correlation,
1
0.4   
4
Nu 
hD  1 2
3
 2  0.4 Re  0.06 Re Pr  
2
(5.39)
k    s 

 Equation (3.38) is valid for 3.5≤Re≤ 80,000 and

0.7≤Pr≤380.
 The fluid properties are evaluated at film temperature
except s which is evaluated at the surface temperature,
Ts.

36
Example 5.2
2. A preheater involves the use of condensing steam at
1000C on the inside of bank of tubes to heat air that
enters at 1atm and 250C. The air moves at 5m/s in cross
flow over the tubes. Each tube is 1m long and has an
outside diameter of 10mm. The bank consists of 196
tube in a square, aligned array for which ST=SL=15mm.
What is the total rate of heat transfer to the air’?
Solution

37
Atmospheric air (T∞=298K): =15.8x10-6m2/s,
k=0.0263W/mK, Pr=0.707, cp=1007J/kgK, =1.17kg/m3;
(Ts=373K): Pr=0.695
The total heat transfer rate
.
Q  hNDL
Ts  Ti   Ts  To   hNDLT
lnTs  Ti  / Ts  To 
lm

ST 15 15  0.01
Vmax  V   5  15 m / s, Re D,max  6
 9494
ST  D 5 15 .8  10

From tables 5.2 and 5.3, C = 0.27, m = 0.63 and C2=0.99.

38
From the Zhukauskas correlation

Nu D  0.99  0.279494 0.7070.36 0.707 / 0.6951/ 4  75.9

0.63

h  Nu D k / D  75.9  0.0263/ 0.01  200W / m 2 .K

  
Ts  To  Ts  Ti  exp 
DN h 
 VN S c 
 T T p 

   0.01196 200 
 75 exp  
 1.17  5 14  0.0151007 
 27.7 0 C
Hence,
. 75  27.7
Q  hNDLTlm  200196  0.011  58.5kW
ln75 / 27.7 

39
5.7 FLOW IN TUBES

Fig. 5.7 Hydrodynamic boundary layer development in tube

40
Fig. 5.8 Thermal boundary layer development in tube
41
5.7 FLOW IN TUBES…
 The Reynolds number for flow in a circular tube is
defined as u m D
Re D 
 (5.40)
Where, ρ is the fluid density
D is tube diameter
 is fluid dynamic viscosity
um is the average fluid velocity given by
.
m (5.41)
um 
.
A
Where m is mass flow rate of fluid.
42
5.7 FLOW IN TUBES…
 In a fully developed flow the critical Reynolds
number is 2300.
 The pressure drop during the flow is given by
L um
2
P  f (5.42)
D 2

Where f is the friction factor and L is tube length

 For laminar and turbulent flows the hydrodynamic
entry lengths may be obtained from
(5.43)
x fd ,h  0.05 Re D D
lam

(5.42)
x fd ,h  10D
turb
43
5.7 FLOW IN TUBES…
 For laminar and turbulent flows the thermal entry
lengths may be obtained from
x fd ,t  0.05 Re D Pr D (5.45)
lam

x fd ,t  10D (5.46)
turb

Laminar flow
 For hydrodynamically developed laminar flow in a
tube, the velocity profile is profile is parabolic and
given by
r2 (5.47)
u (r )  2u m (1  2
)
ro
44
5.7 FLOW IN TUBES…
 And the surface shear stress is
du 8u m (5.48)
 s  2 
dr r  ro D
 The surface shear stress can also be written as

u m2 (5.49)
s  Cf
2

 It follows from equations (5.47) and (5.48) that the

friction coefficient Cf can be given as
16
Cf  (5.50)
Re D
45
5.7 FLOW IN TUBES…
 The friction factor f used in the pressure drop
calculation in laminar flow is given by
64
f  (5.51)
Re D
 The average Nusselt number for the hydrodynamically
or thermally developed laminar flow is given by Sider
and Tate
1
3
 
0.14 (5.52)
hD 
Re Pr D   b
Nu   1.86    
k  L  s

 All the properties are evaluated at bulk mean fluid

temperature, except for s, which is evaluated at the
surface temperature.

46
5.7 FLOW IN TUBES…
Turbulent flow
 The friction factor for fully developed turbulent flow in a
smooth tube is given by
(5.53)
f  0.184 Re D0.2

 For flows in smooth or rough tubes the friction factor is

obtained from Moody diagram of Fig. 5.9.
 The friction factor can be obtained from the Colebrook
equation for flows in smooth or rough tubes in transition
and turbulent flows.
1   .D 2.51  (5.54)

 2.0 log 
 f 
f  3.7 Re
 The average Nusselt number for turbulent flow in a tube is
given from the Chilton-Colburn correlation as
1
Nu D  0.125 f Re Pr 3 (5.55)
47
5.7 FLOW IN TUBES…

Fig. 5.9 The Moody Diagram

48
 5.7 FLOW IN TUBES…
Table 5.4 Roughness Values for Commercial Ducts

Material Condition ε (mm)

Steel Sheet metal, new 0.05
Stainless, new 0.002
Commercial, new 0.046
Riveted 3.0
Rusted 2.0
Iron Cast, new 0.26
Wrought, new 0.046
Galvanized, new 0.15
Asphalted cast 0.12
Brass Drawn, new 0.002
Plastic Drawn tubing 0.0015
Glass - 0 (smooth)
Concrete Smoothed 0.04
Rough 2.0
Rubber Smoothed 0.01
Wood Stave 0.5

49
Example 5.3
3. An engine oil cooler consists of a bundle of 25 smooth
tubes, each of length L=2.5m and diameter of D=110mm.
a) If oil at total flow rate of 24kg/s is in fully developed
flow through the tubes, what are the power drop and the
pump power requirements?
b) Compute and plot the pressure drop and pump power
requirement as a function of flow rate for 10-30kg/s.
Solution

50
Properties of Engine oil (300 K): r=884kg/m3,
μ=0.486kg/s.m.

a) Considering flow through a single tube

.
4m 4  24
Re D    251 .5
D 25  0.01  0.486

Hence, the flow is laminar and

64 64
f   0.2545
Re D 251 .5

.
m1 24 / 25
um    13.8m / s
 2
 
 D / 4 884  0.01 / 4
2

51
 The pressure drop is,
u m2 884  13 .8 2
p  f L  0.2545   2.5  5.38  10 6 N / m 2  5.38 Mpa
2D 2  0.01

The pump power required is

.
. m 24
P  p V  p  5.38  106   146 kw
 884

52
b) Plot of pressure drop and pump power

53
Example 5.4
4. Water at 150C (=999.1kg/m3 and =1.138x10-3 kg/ms) is
flowing in a 4cm diameter and 30m long horizontal pipe
made of new stainless steel steadily at a rate of 5L/s.
Determine:
(a) The pressure drop and
(b) The pumping power requirement to overcome this
pressure drop.

Water D = 4 cm
5 L/s

L = 30 m
54
Solution
The density and dynamic viscosity of water are given to
be (=999.1kg/m3 and =1.138x10-3 kg/ms, respectively.
The roughness of new stainless steel is 0.002 mm
(Table 5.4).
First we calculate the mean velocity and the Reynolds
number to determine the flow regime:
V V 0.005 m 3 / s
Vm     3.98 m / s
Ac D / 4  (0.04 m) / 4
2 2

Vm D (999.1 kg/m 3 )(3.98 m/s)(0.04 m)

Re    1.40  10 5
 1.138  10 3 kg/m  s
which is greater than 10,000.
 Therefore, the flow is turbulent.
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 The relative roughness of the pipe is

2 10 6 m
/D  5 10 5
0.04 m

 The friction factor can be determined from the Moody

chart, but to avoid the reading error, we determine it
from the Colebrook equation using an equation solver
(or an iterative scheme),

1  / D 2.51  1  5 10 5 2.51 

 2.0 log      2.0 log   
f  3.7 Re f  f  3.7 1.40 10 5 f 
  

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 It gives f = 0.0171. Then the pressure drop and the required
power input become
(a)
L ρVm
2
ΔP  f
D 2
30 kg/m 3 )(3.98
m (999.1 m/s 2  1
kN  1 kPa 
 0.0171   2 
0.04m 2  1000
kg  ms  1
kN/m 
 101.5kPa

(b)  1 kW 
W pump,u  VP  (0.005 m 3 / s )(101.5 kPa )   0.508 kW
 1 kPa  m /s 
3

 Therefore, useful power input in the amount of 0.508 kW

is needed to overcome the frictional losses in the pipe.

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