Heat Transfer by Free and Forced

Convection

Steven Manole

ME 406

Prof. Koplik

March 27, 2013

 Abstract

The flow of heat through a condenser tube wall differs depending on whether or not the

condenser experiences free or forced convection. By measuring the temperature difference across the

tube wall for both of these cases, the overall heat transfer coefficient can be be determined. In addition

to the heat lost through the condenser wall, the entire system loses heat due to the combined effect of

convection and radiation. These losses are estimated using the overall heat transfer coefficient.
 Table of Contents

Introduction ............................................................................................. 1

Procedure .................................................................................................... 2

Theory ..................................................................................................... 5

Sample Calculations ................................................................................ 6

Results ..................................................................................................... 7

Analysis ................................................................................................... 9

Conclusion ............................................................................................... 11

References ............................................................................................... 12

Appendix ..................................................................................................13
 Manole 1

Introduction

Dealing with heat transfer in a condenser is made all the more difficult due to the fact that the

cooled vapor forms a film of droplets on the surface of the condenser. This film serves to cover the

cooler surface of the condenser wall, preventing further vapor from forming a condensate. Condensers

are built to be vertical, so that the droplets of film are able to drain from the surface more rapidly. This

creates an interesting effect, as the thickness of the film on the lower surface is much greater than the

thickness on the higher surface due to gravity. Therefore, the upper portion is much more effective at

transferring heat. Since it can be difficult to calculate the heat transfer of such a complicated problem, it

is advantageous to find an overall heat transfer coefficient.

 Manole 2

Procedure

Figure 1 Experimental System of Boiler and Condenser

The system used in this experiment is diagrammed in Figure 1. The boiler (B) is fed by a water

supply tank (A). After being heated into steam by the boiler, the vapor enters the condenser (C). Here,

it condenses into droplets on the surface and is received through the exit at the bottom. Simultaneously,

cooling water is fed into the head control tank (D). This tank is connected to the cooling tube, which

passes the cool water through the center of the condenser. This cooling water, which has increased in

temperature considerably, exits the condenser and is received by a tank (E).

Each aspect of this system serves a purpose. The boiler supply tank limits the level of water
 Manole 3

inside the boiler, ensuring that the mass of the system remains constant. The condenser works through

the use of cooling water that passes upward through the condenser tube, causing the steam to condense

on the outside surface of the cooling tube. The steam also condenses on the inside surface of the

condenser jacket due to heat escaping from the system into the room. The head control tank manages

the level of the cooling water, allowing for forced or free convection depending on the height of the

water.

The experiment is performed at both forced and free convection levels for twenty minutes each.

During the experiment, the condensate is collected and its volume measured from the exit of the

condenser. The weight of cooling water collected in the tank is also measured. At certain points

throughout the system, thermocouples are attached to provide temperature readings. The locations of

these thermocouples are shown in Figure 1, and compiled in Table 1. These temperatures are recorded

four times for each run, and averaged for a final result.
 Manole 4

Table 1: Location of Thermocouples

Designation Location

T1 Steam in

T2 Cooling Water Out

T3 Cup Condensate Out

T4 Tube Wall Condensate Out

T5 Condenser Surface Outside

T6 Boiler Surface Outside

T7 Cooling Water Bottom

T8 Cooling Tube Surface Upper

T9 Cooling Tube Surface Lower

T10 Condenser Steam Inside

T11 Room

T12 Cooling Water Supply Tank

 Manole 5

Theory

The rate of change of heat in a cooling fluid can be calculated from a simple thermodynamic

relationship:

q= mc T (1)

Where m represents the rate of change of mass, c the heat capacity of the fluid, and T the

change in temperature. In addition, the rate of change of heat in a condensing gas can be found through:

q=H v m (2)

Since the condensing steam first cools, then undergoes a phase change to water, and cools further, the

total heat loss for this process can be found by summing all three of these losses. In order to perform

these calculations, however, the initial and final temperatures must be found. Using Figure 1 in the

previous section, the designations for the required temperatures can be located. Of note is the final

value of the condensate, which is the average of T3 and T4. The condensate is collected both on the

wall of the condenser and the wall of the cooling tube, so both values must be averaged.

Equation (1) is used once again to determine the rate of change of heat in the cooling water. It

will be assumed that all heat not lost to the cooling water is lost through the wall of the condenser. This

means that the rate of change of heat through the condenser wall is the difference between the

magnitude of heat lost by the condensing steam, and the heat lost to the cooling water. Finally, in order

to find the overall heat transfer coefficient:

q
U 0= (3)
A surface T
 Manole 6

Sample Calculations

The properties are taken at temperature of exiting condensate = 199 F

V 0.963 g/mL515 mL
m= = =1487.8 g/hr
t 20 min1/60 hr/min

( T 3+ T 4 )
qcondensate =mc water(T 10 )
2
(199+ 200)
qcondensate =1487.8 g/hr1 Btu/lb F( 205 ) F0.0022 lb/g=20.13 Btu/hr
2

q phase =H vm=2.26 kJ/g0.948 Btu/kJ1487.8 g/hr=3187.7 Btu/hr

The properties are taken at average steam temperature = 210F

qsteam =mc steam( T 1T 10)=1487.8 g/hr0.4515 Btu/lb F( 216205)F0.0022 lb/g=15.14 Btu/hr

qtotal = q condensate + q phase + qsteam =20.133187.715.14=3222.9 Btu/hr

The properties are taken at room temperature = 77.2 F

117 oz
qcooling = mc water(T 2T 7)= 0.997 Btu/lb F(19174)F=2548.6 Btu/hr
20 min
16 oz/lb
60 min/hr

q outerwall = qtotal + q cooling=3222.9+ 2548.6=674.3 Btu/hr

51
Asurface =dh= 25=250.3 in^2
16

qouterwall 674.3 Btu/hr

U 0= = 144 in^2/ft=38.4 Btu/hr ft^2 F
Asurface(T 3T 4) 250.3 in^2(199191) F
 Manole 7

Results

Free Convection
Water Quantity Thermocouple (F)
Cup Tube Wall Condenser
Bolier Feed Cooling Water Cooling Water Boiler Surface
Time (min) Steam In Condensate Condenser Surface
(mL) (oz) Out Outside
Out Out Outside
T1 T2 T3 T4 T5 T6
0 0 296 214.7 193 204 205 198 209
5 125 322 215.4 190.5 191.8 182.8 193.7 209.6
10 130 352 215.9 192.7 204.2 205.5 197.6 209.6
15 135 382 216.2 185.9 194.9 205 198.4 210.2
20 125 413

Total 515 117

Average 215.55 190.525 198.725 199.575 196.925 209.6

Thermocouple (F) Thermometer (F)

Cooling Tube Cooling Tube
Cooling Water Condenser Cooling Water
Surface Surface Room Watts
Bottom Steam Inside Supply Tank
Upper Lower
T7 T8 T9 T10 T12 T11
74 200 170.2 207.3 68.7 76.1 1100
72.8 188.4 165 202.2 69.2 77 1100
74.3 197.5 174.4 208 69.8 77.6 1100
74.9 199.1 171.2 203.7 70.3 78.1 1100
1100

74 196.25 170.2 205.3 69.5 77.2 1100

Take at T (F) Take at T (F) Take at T (F)

199.15 210.425 77.2
del_q
Cylinder Area Mass/Time del_q phase del_q steam del_q total del_q cooling
condensate
(in^2) (g/hr) (Btu/hr) (Btu/hr) (Btu/hr) water (Btu/hr)
(Btu/hr)
250.345664583 1487.835 -20.13040755 -3187.656731 -15.14813168 -3222.93527 2548.5983859

Tube Area
(in^2)
61.3592315154

del_q
U_0 (Btu/hr U_0 (Btu/hr h2 (Btu/ hr
condenser
in^2 F) ft^2 F) ft^2 F)
wall (Btu/hr)
-674.3368841 0.2666953639 38.404132408 18.931052347

U_cool
(Btu/hr ft^2 F)
117.36355598
 Manole 8

Forced Convection
Water Quantity Thermocouple (F)
Cup Tube Wall Condenser
Bolier Feed Cooling Water Cooling Water Boiler Surface
Time (min) Steam In Condensate Condenser Surface
(mL) (oz) Out Outside
Out Out Outside
T1 T2 T3 T4 T5 T6
0 0 468 217 111.9 188.4 184 178.6 211.2
5 150 584 217 105.2 183 174.1 174 210.6
10 120 676 217.3 113 190 181 176.5 211.3
15 140 776 217.5 103 183.7 176.1 175.4 211.8
20 140 870

Total 550 402

Average 217.2 108.275 186.275 178.8 176.125 211.225

Thermocouple (F) Thermometer (F)

Cooling Tube Cooling Tube
Cooling Water Condenser Cooling Water
Surface Surface Room Watts
Bottom Steam Inside Supply Tank
Upper Lower
T7 T8 T9 T10 T12 T11
74.1 139.1 154.2 207.3 70.1 78.7 1100
74 133.6 153.4 202.2 70.2 79 1100
72.1 129.8 149.1 209 66.9 79.6 1100
67.1 129.5 143.5 203.7 60.8 79.5 1100
1100

71.825 133 150.05 205.55 67 79.2 1100

Take at T (F) Take at T (F) Take at T (F)

182.5375 211.375 79.2
del_q
Cylinder Area Mass/Time del_q phase del_q steam del_q total del_q cooling
condensate
(in^2) (g/hr) (Btu/hr) (Btu/hr) (Btu/hr) water (Btu/hr)
(Btu/hr)
250.345664583 1588.95 -80.44456613 -3404.293596 -18.38724201 -3503.125404 2739.1764938

Tube Area
(in^2)
61.3592315154

del_q
U_0 (Btu/hr U_0 (Btu/hr h2 (Btu/ hr
condenser
in^2 F) ft^2 F) ft^2 F)
wall (Btu/hr)
-763.9489104 0.4015232045 57.819341445 28.134428976

U_cool
(Btu/hr ft^2 F)
124.88383914
 Manole 9

Analysis

From the results, it has been determined that the coefficient of overall heat transfer, U_0, is 38.4

Btu / (hr-in^2-F) for free convection and 57.8 Btu/ (hr-in^2-F) for forced convection. This makes sense,

as it would be expected that more heat be transferred through forced convection versus free convection.

Through the equation:

r2
r 1 ln( )
1 r1 1 r1
=R= + + (4)
U0 k A1 h1 A1 h2 r 2 A1

one can estimate the expected value for U_0. However, since there is no film on the outside of the

condenser, the convection coefficient h_2 does not come from the values for film coefficients. The

other heat transfer coefficients, however, can be estimated. The conduction coefficient through the

condenser wall, k, is about 25 Btu / (hr-ft-F) for steel. For the purpose of this analysis, let it be assumed

at first that the heat transfer coefficient h_1 is much larger than h_2. Therefore, it is simple to assume

the U_0 to be known as estimated in the results, and calculate h_2:

r1 U
h 2= (5)
r2 r
U r 1 ln( 2 )
r1
A 1
k

The resulting values for h_2 are 18.9 Btu / (hr-ft^2-F) for free convection and 28.1 Btu / (hr-ft^2-F) for

forced convection. Solving now for h_1:

1
h1 = (6)
r ln(r 2 /r 1 ) r
A1 R 1 1
k r2 h 2

yields h_1 = 416.8 Btu/(hr-ft^2-F) for both free and forced convection. Since h_1 >> h_2, the

assumption made when calculating h_2 holds.

 Manole 10

The convection coefficient for free convection of air should vary between 0.88 and 4.41 Btu/

(hr-ft^2-F). Since h_2 for free convection was 18.9 Btu/(hr-ft^2-F), this value is much higher than

would be expected. The reasons for such a differing value are discussed in the conclusion. For forced

convection, the value for h_2 was within the range of expected values. The convection coefficient

should be between 1.76 and 35.25 Btu/(hr-ft^2-F), so 28.1 Btu/(hr-ft^2-F) is a reasonable result.

Using empirical values for U_0 is another method that can be used to validate these results. The

expected value for U_0 in a steam-water condenser is between 350 and 750 Btu/(hr-ft^2-F). The results

of 38.4 and 57.8 Btu/(hr-ft^2-F) are far below these expected values. However, the heat transfer

through the condenser tube wall is not the only source of heat loss. In addition, there is also the heat

transfer to the cooling water, which is much larger than the heat transfer through the condenser tube

wall. The values for the overall heat transfer coefficient to the cooling water are 117.4 and 124.9 Btu/

(hr-ft^2-F) for free and forced convection respectively. In addition, it is likely that there are other

sources of heat loss, as the system was not perfectly insulated. It is reasonable to assume that these

combined sources of heat loss will result in an overall heat transfer coefficient for the system that is

within the expected range.

The total rate of heat loss from the equipment can be estimated using thermodynamics analysis

on the condensing steam. The heat lost from the system must be equivalent to the sum of the heat lost

from the temperature changes of the steam and water, and the phase change from steam to water. This

total rate of heat loss has been estimated to be 3223 Btu/hr for free convection and 3503 Btu/hr for

forced convection. To check if this estimate is reasonable, consider that 1100W of power entered the

system. Therefore, the same amount of heat should be leaving the system, as long as the overall

temperature of the system is not increasing. 1100 W is equal to 3753 Btu/hr, so this estimate is very

reasonable.
 Manole 11

Conclusion

The results of the experiment had strong correlations with empirical observations. This both

confirms the empirical results and validates the experimental results. However, there were still some

disparities between the empirical and experimental values. The value furthest from the expected value

was the convective heat transfer coefficient for air for free convection. At a value of 18.9 Btu/

(hr-ft^2-F), it was far from the expected interval of 0.88 to 4.41 Btu/(hr-ft^2-F). One reason for this

error could be that the free convection was not perfect, and at times, the heat transfer problem

resembled that of forced convection. Since there was human error in determining the level of the

cooling water, it is reasonable to assume that the water level may have been too high during this portion

of the experiment. Another explanation could be that there were minor air currents in the room, causing

a mild forced convection phenomenon.

Another result that warrants explanation is the difference between the power input into the

system of 3753 Btu and the resulting heat losses of only 3223 and 3503 Btu. Since the temperature of

the system remained constant, the heat into the system should equal the heat leaving the system.

However, only the heat lost inside the condenser was accounted for. The difference in heat can be

explained by the heat lost between the boiler and the condenser. Since that portion of the system was

not perfectly insulated, some of the power that entered the system left as heat before even entering the

condenser.
 Manole 12

References

"Convective Heat Transfer." Engineering Toolbox. Web. 16 Apr. 2013.

"Heat of Fusion." Kent Chemistry. N.p., n.d. Web. 16 Apr. 2013.

"Heat Transfer Coefficients Typical Values." H & C Heat Transfer. N.p., n.d. Web. 16 Apr. 2013.

ME 406 Lab Manual. Heat Transfer by Free and Forced Convction. Sept 2005.

"Water - Thermal Properties." Engineering Toolbox. N.p., n.d. Web. 16 Apr. 2013.

"Water Vapor - Specific Heat." Engineering Toolbox. N.p., n.d. Web. 16 Apr. 2013.