METALLURGY AND FOUNDRY ENGINEERING – Vol. 37, 2011, No.

Krzysztof Karczewski*

SIMPLIFIED METHOD OF HEAT CALCULATIONS

OF OIL-AIR HEAT EXCHANGERS

Notation:

α – convection heat-transfer coefficient, W/(m2·K)

c – mean heat capacity, kJ/(m3·K)
d – diameter, m
F – heating surface area, m2
k – over-all heat-transfer coefficient, W/(m2·K)
L – height of fin, m
λ – thermal conductivity, W/(m·K)
m – parameter of fin, m
M – mass rate of fluid flow, kg/s
p – pitch of fines, m
r – radius, m
s – thickness of fin, m
t – temperature, K
ρ – density, kg/m3
μ – viscosity coefficient, kg/(m·s)
w – velocity, m/s
V – volumetric rate of fluid flow, m3/s
Q – heat transfer rate, W
η – efficiency

* Ph.D.: AGH University of Science and Technology, Faculty of Metals Engineering and Industrial
Computer Sciences, Krakow, Poland; e-mail: ztc@agh.edu.pl

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1. INTRODUCTION

New constructions of heat exchangers require research on the intensification of heat

transfer realized by Mean Direct Action on the Flow or Surface Development methods [1, 4, 5].
Intensification of heat transfer in exchanger increases over-all heat transfer coefficient and
efficiency, also reduces construction materials costs. For calculation of heat exchangers de-
signs Mean Temperature Difference method and Heat Effectives one are used [6, 8]. The both
methods are based on universal equal of energy balance. The aim this paper is new method of
calculations oil-air exchangers made of cross-finned aluminium pipes.

2. UNIVERSAL EQUATIONS OF HEAT TRANSFER

Heat transfer rate of oil-air exchangers is described by equations (1, 2):

Q = Va ca (ta′′ − ta′ ) (1)

where:
Va – volumetric rate of air flow,
ca – mean heat capacity of air,
ta′ – inlet air temperature,
ta′′ – outlet air temperature.

(
Q = kF t f − ta ) (2)

where:
k – over-all heat transfer coefficient,
F – heating surface area,
t f – mean temperature of oil,
ta – mean temperature of air.

Over-all heat transfer coefficient [1, 8] is:

1
k= (3)
ϕo 1
+
α f αr

where:
α f – convection heat transfer coefficient from oil to wall,
α r – reduced heat transfer coefficient,
ϕo – finning ratio.

160
 F
ϕo = (4)
Fr

where:
F – surface finned area,
Fr – surface area of smooth pipe.

Influence of efficiency on heat transfer describes reduced heat-transfer coefficient by

equation:

⎛F F ⎞
α r = αo ⎜ m + ¿ η ⎟ (5)
⎝ Fr Fr ⎠

where:
α o – convection heat-transfer coefficient of smooth element,
Fm – surface area between fins,
F¿ – surface area of fins,
Fr – surface area of smooth pipe,
η – efficiency.

Figure 1 illustrates the cross-finned pipe with circular fins of constant thickness.

Fig. 1. The cross-finned pipe: dw – inner diameter of pipe, d1 – outer diameter of pipe, d2 – outer
diameter of finned pipe, L – height of fin, s – thickness of fin, p – pitch of fines

For diameters ratio of pipe d1/dw < 2 it is possible to calculate over-all heat-transfer
coefficient as for plane wall [7], by equation (3).

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3. RESEARCH OF ELEMENTS OF THE HEAT EXCHANGERS
MADE OF CROSS-FINNED ALUMINIUM PIPES

The tested element of heat exchangers has the following geometric, flow, and tempera-
ture parameters:
– inner diameter of element dw = 0.025 m,
– outer diameter of element d1 = 0.030 m,
– outer diameter of finned element d2 = 0.052 m,
– height of fin L = 0.011 m,
– thickness of fin s = 0.00045 m,
– pitch of fin p = 0.00252 m,
– inlet air temperature ta′ = 18.3 oC,
– outlet air temperature ta′′ = 23.5 oC,
– inlet oil temperature t ′f = 70.1 oC,
– outlet oil temperature t ′′f = 66.6 oC,
– mass rate of oil flow Mf = 0.35 kg/s,
– volumetric rate of air flow Va = 0.365 m3/s,
– surface area of air flow Fa = 0.00317 m2,
– surface area of oil flow Ff = 0.0112 m2,
– lenght of element l = 0.295 m,
– simplex of diameters d1/d2 = 1.2,
– quantity of elements n = 23,
– heat surface area of exchanger F = 1.15 m2.

According to Schmidt [9] efficiency of circular fin is described by equation:

tgh ( mLc ϕ )
η= (6)
mLc ϕ

where:
⎛ L ⎞ ⎛ 0.0114 ⎞
ϕ = 1 + 0.35 ln ⎜1 + c ⎟ = 1 + 0.35ln ⎜ 1 + ⎟ = 1.198,
⎝ r1 ⎠ ⎝ 0.015 ⎠

Lc = r2c – r1 = 0.0264 – 0.015 = 0.0114 m,

d 0.030
r1 = 1 = = 0.015 m,
2 2

162
 d 0.052
r2 = 2 = = 0.026 m,
2 2

d + s 0.052 + 0.00045
r2c = 2 = = 0.0264 m.
2 2

Parameter of fin is:

2α 2 ⋅ 45.4
m= = = 34.96 m,
λs 165 ⋅ 0.00045

where:
convection of heat-transfer coefficient delivered to surface area of smooth pipe
αo = 45.4 W/(m2⋅K),
thermal conductivity of aluminium ë = 165 W/(m⋅K),
thickness of fin s = 0.00045 m,
m · Lc = 34.96 · 0.0114 = 0.399 m2,

tgh (34.96 ⋅ 0.0114 ⋅1.198 )

η= = 0.97.
34.96 ⋅ 0.0114 ⋅1.198

According to Brandt [9] efficiency of circular fin is described by equation:

2r1 tgh mLc ⎡ tgh mL

⎢1 + c (tgh mLc )3.7482 ⎤⎥
η= + 0.071882 (7)
2r1 + Lc mLc ⎢
⎣
2mr1 ( mr1 )1.481 ⎥⎦
where:
r1 = 0.015 m, Lc = 0.014 m, m = 34.96 m.

2 ⋅ 0.015 tgh 34.96 ⋅ 0.014 ⎡ tgh (34.96 ⋅ 0.014 )

η= ⎢1 + +
2 ⋅ 0.015 + 0.014 34.96 ⋅ 0.014 ⎣ 2 ⋅ 34.96 ⋅ 0.015

+0.071882
(tgh 34.96 ⋅ 0.015)3.7482 ⎤⎥ =
0.93.
(34.96 ⋅ 0.015)1.481 ⎥⎦
Efficiency of circular fin is described [9] also by equation:
1
η= (8)
1 2 r2c
1 + ( mLc )
3 r1

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where:

mLc = 0.399 m2, r2c = 0.0264 m, r1 = 0.015 m.

1
η= = 0.93.
1 2 0.0264
1 + (0.399 )
3 0.015

4. RESEARCH OF HEAT TRANSFER COEFFICIENTS

Heat transfer coefficient on oil side

Surface area of oil flow is:

πd w2 π ⋅ 0.0252
F f = 23 = 23 = 0.0112 m 2 .
4 4

Velocity of oil is:

Mf 0.35
wf = = = 0.036 m/s,
ρF f 864 ⋅ 0.0112

where: density of oil ρf = 864 kg/m3.

Reynolds number is:

w f d wρ f 0.036 ⋅ 0.025 ⋅ 864

Re = = = 128.4,
μ 60.558 ⋅10 −4

where:
70.1 + 66.6
mean temperature of oil t f = = 68.4 o C,
2
dynamic viscosity coefficient of oil [10] μ = 60.558 · 10–4 kg/(m·s).

According to Mikheyev [7] for laminar flow of oil heat transfer coefficient is described
by similarity equation:

0.4
⎛d ⎞
Nu = 1.4 Re0.4 Pr 0.33 ⎜ ⎟ (9)
⎝l ⎠

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 Prandtl number is:

cf μ 2.137 ⋅ 60.558 ⋅10−4

Pr = = = 107.0,
λf 0.121

where:
thermal conductivity of oil [10] λf = 0.121 W/(m⋅K),
mean heat capacity of oil [10] cf = 2.137 kJ/(kg⋅K).

Nusselt number is:

α f dw α f 0.025 0.4
⎛ 0.025 ⎞
Nu = = = 1.4 ⋅128.40.4 ⋅1070.33 ⎜ ⎟ ,
λ 0.121 ⎝ 0.295 ⎠

hence heat-transfer coefficient

αf = 82.0 W/(m2⋅K).

Heat-transfer coefficient on air side

Velocity of air is:

V 0.365
wa = a = = 11.5 m/s,
Fa 0.00317

According to Schack [3] convective heat-transfer coefficient for smooth element is:

wa0.8 11.50.8
αo = (3.5 + 0.00185 ta ) = (3.5 + 0.00185 ⋅ 20.9 ) = 45.4 W/(m 2 ⋅ K),
d 20.2 0.0520.2

where:
outer diameter d2 = 0.052 m,
18.3 + 23.5
mean temperature of air ta = = 20.9 o C.
2

The surface area of fin is:

( ) (
F¿ = 2π r22 − r12 = 2π 0.0262 − 0.0152 = 0.00283 m 2 . )
The surface area of smooth pipe on one pitch is:

Fr = 2πr1 p = 2π ⋅ 0.015 ⋅ 0.00254 = 0.000239 m2 .

165
 The inner surface area of pipe is:

Fw = 2πrw p = 2π ⋅ 0.012 ⋅ 0.00254 = 0.00191 m2 .

The surface area between fins on one pitch is:

Fm = Fr − πd1s = 0.000239 − π ⋅ 0.030 ⋅ 0.00045 = 0.000197 m 2 .

The reduced convection heat-transfer coefficient is:

⎛F F ⎞ ⎛ 0.000197 0.00283 ⎞
α r = α ⎜ m + ¿ η ⎟ = 45.4 ⎜ + ⋅ 0.95 ⎟ = 548.1 W/(m 2 ⋅ K).
⎝ Fr Fr ⎠ ⎝ 0.000239 0.000239 ⎠

The over-all heat transfer coefficient calculated by equations (3) and (4) is:

1 1
k= = = 42.0 W/(m 2 ⋅ K).
ϕo 1 1.8 1
+ +
α f αr 82 548.1

where:
F .15
ϕo = = = 1.8.
23 ⋅ πd1 ⋅ l 23 ⋅ π ⋅ 0.03 ⋅ 0.295

The heat-transfer ratio of heat exchanger is:

Q = Va · ca (ta′′ − ta′ ) = 0.365 · 1.28 (23.5 – 18.1) = 2.43 kW.

The mean temperature difference is:

Δtm = t f − t p = 68.4 – 20.9 = 47.5 oC.

The over-all heat-transfer coefficient calculated by equation (2) is:

Q 2340
k= = = 45.0 W/(m2 ⋅ K).
F Δtm 1.15 ⋅ 47.5

The calculation error of over-all heat-transfer coefficient is:

45 − 42
Δ= ⋅100 = 6.7.
45

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5. INFERENCES

– Model researches carried out on an experimental post and heat calculations make possi-
ble the identification of over-all heat-transfer coefficient in oil-air heat exchanger made of
aluminium cross-finned pipes with circular fins.
– Difference of the value of over-all heat transfer coefficient calculated by simplified meth-
od and Mean Temperature Difference one comes to 6.7%.
– Influence efficiency of fin on heat transfer is described by the reduced heat transfer
coefficient.
– The maximal difference between efficiency of fin calculated by three methods comes to
4.0%.
– Elaborated simplified method makes possible the identification of construction parame-
ters and designed oil-air heat exchangers.

Acknowledgements
The financial support from the Polish Ministry of Science and Higher Education, con-
tract AGH No. 11.11.110.935 is gratefully acknowledged.

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Received
October 2011

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