Problem Solutions in Heat Transfer

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Problem Solutions in Transport Phenomena: Heat Transfer Problems
For theory relevant to the heat transfer problems below, please refer to the book: Bird, R. B., Stewart, W. E., and Lightfoot, E. ., !"ransport #henomena!, $nd edition, %ohn Wiley, ew &ork'$(($). "he sol*tions below will also help yo* solve some of the problems in BSL 'an abbreviation often *sed for this +lassi+ tetbook based on the initials of its a*thors).
Maximum current in an electric wire
Problem
 An electric wire with radius
0
 of 0.50 mm is made of copper [electrical conductivity  5.! " !0
#
ohm
$!
 m
$!
 and thermal conductivity  %&0 '()m *+,. -t is insulated )see fiure+ to an outer radius
!
 of !.50 mm with plastic [thermal conductivity  0.%50 '()m *+,.
Figure:
 Heatin of an insulated electric wire. The ambient air is at %&.0
o
/ and the heat transfer coefficient from the outer insulated surface tothe surroundin air is &.500 '()m
 *+. 1etermine the ma"imum current in amperes that can flowat steady$state in the wire without any portion of the insulation ettinheated above itsma"imum allowable temperature of 2%.0
o
/.
Solution
 Step. Thermal resistance representation for insulation and air  -n eneral3 the heat flow is iven by
Q
 
(
 R
th
3 where
 is the temperature drivin force)thermal potential difference+. The thermal resistance for a cylindrical annulus is
 R
th
  ln )
!
(
0
+()
 
 
kL
+ and the thermal resistance for a fluid film at a solid$fluid interface is
 R
th
  !()
hA
+. Here3!
 
 is the thermal conductivity3
h
 is the heat transfer coefficient and
 A
 is the surface area for convection. The thermal resistances for the insulation and air film are in series as shown in the fiure below.
Figure:
 Thermal resistance representation of insulation and air film 4ased on the above thermal resistance representation3 the heat flow is
 LhkL  Rwhere RQ
thth
 !0!0
!+(ln)
  
)!+where
 is the thermal conductivity of the plastic insulation. Step. Heat flow due to current in wire The flow of an electric current results in some electrical enery ettin converted to thermalenery irreversibly. The heat eneration by electrical dissipation per unit volume is iven by
 
 I 
 
(
e
 where
 I 
 is the current density )in amp(m
+ and
e
 is the electrical conductivity )in ohm
$!
 m
$!
+.The total heat enerated within the wire is simply the product of
 and the volume of the wire. Atsteady$state3 all this heat enerated within the wire by electrical dissipation must leave throuhthe wire surface and therefore the heat flow is iven by
 L I Q
e
0
 
)+Step. "pression for current 6n eliminatin
Q
 from the above two e7uations3 the current density is
    
0(!!0!0
 !+()!(+(ln) +)
hr   I 
 e
)%+6n multiplyin the current density by the cross$sectional area of the wire3 the current is obtained from
0(!!0!00
+()!(+(ln) +)
hr   I Current 
 e
  
)8+9or the ma"imum current3 the temperature
0
 must be ma"imied. Step. Substitution of numerical values 
5
 
6n settin the temperature
0
 to 2%.0
o
/ )i.e.3 the ma"imum allowable temperature for theinsulation+3 the ma"imum current that can flow throuh the wire may be calculated as !%.0#amp. The numerical values substituted in the e7uation are iven below. The values below may be chaned and the problem solution recalculated with the new values  provided in consistent units. ;ariable nameSymbol;alue<nitelectrical conductivity
 
e
 51000000
ohm
$!
 m
$!
ma"imum temperature
 
0
 93.0000
o
/ambient temperature
 
 38.0000
o
/outer radius
 
!
 0.001500
mwire radius
 
0
 0.000500
m plastic thermal conductivity
 
 0.35000
'()m *+heat transfer coefficient
 h
 8.50000
'()m
 *+/alculated ;ariableSymbol;alue<nit=a"imum current!%.0#amp
Recalculate
Minimum thickness for a composite furnace wall 
Problem
 The wall of a furnace comprises three layers as shown in the fiure. The first layer is refractory)whose ma"imum allowable temperature is !800
o
/+ while the second layer is insulation )whosema"imum allowable temperature is !02%
o
/+. The third layer is a plate of ?.%5 mm thic@ness of steel [thermal conductivity  85 '()m *+,. Assume the layers to be in very ood thermal contact.%
5
 
Figure:
 ayers in a composite furnace wall. The temperature
0
 on the inside of the refractory is !%#0
o
/3 while the temperature
%
 on theoutside of the steel plate is %#.&
o
/. The heat loss throuh the furnace wall is e"pected to be!5&00 '(m
. 1etermine the thic@ness of refractory and insulation that results in the minimumtotal thic@ness of the wall. Biven thermal conductivities in '()m *+: ayer 
 
 at %#.&
o
/
 
 at !02%
o
/>efractory%.!?.%-nsulation!.5?%.!
Solution
Step. Thermal resistance representation for composite furnace wall -n eneral3 the heat flow is iven by
Q
 
(
 R
th
 and the thermal resistance for a rectanular slabis
 R
th
 
 x
()
kA
+3 where
 is the temperature drivin force )thermal potential difference+3
 x
 isthe slab thic@ness3
 is the thermal conductivity3 and
 A
 is the cross$sectional area of the slab. The thermal resistances for the three layers are in series as shown in the fiure below.
Figure:
 Thermal resistance representation of composite furnace wall4ased on the thermal resistance representation for the composite furnace wall3 the heat flu"
q
 is
%%%!!!0!0!!0
 x x x x x x AQq
)!+-n the refractory and insulation3 the thermal conductivity
 varies with temperature. -f a linear variation is assumed3 then the arithmetic mean is to be used for the thermal conductivity. 8
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