DESIGN AND ANALYSIS FOR HEAT TRANSFER

THROUGH FIN WITH EXTENSIONS

A PROJECT REPORT

Submitted by

AAKASH SUNDAR S (111716114002)

DEEPAKBALAJI V (111714114027)
GANESH KUMAR R (111714114035)

in partial fulfilment for the award of the degree

of

BACHELOR OF ENGINEERING

in

MECHANICAL ENGINEERING

R.M.K. ENGINEERING COLLEGE, KAVARAIPETTAI

ANNA UNIVERSITY:: CHENNAI 600 025

MAY 2020

ANNA UNIVERSITY: CHENNAI 600 025

 BONAFIDE CERTIFICATE

Certified that this project report “DESIGN AND ANALYSIS FOR HEAT
TRANSFER THROUGH FIN WITH EXTENSIONS” is the bonafide work of
“S.AAKASH SUNDAR (111714114002), V.DEEPAKBALAJI (111714114027),
R.GANESH KUMAR (111714114035)” who carried out the project report under my
supervision.

SIGNATURE
Dr. K.R. Senthil Kumar, M.E., Ph.D .,
HEAD OF THE DEPARTMENT,
Professor & Head of the Department
Department of Mechanical Engineering,
R.M.K. Engineering College,
R.S.M. Nagar,
Kavaraipettai - 601206
SIGNATURE
Mr. G. Sivakkumar, M.E.,
SUPERVISOR
Assitant Professor,
Department of Mechanical Engineering,
R.M.K. Engineering College,
R.S.M. Nagar,
Kavaraipettai - 601206

Submitted for the project viva voce held on………......... at R.M.K Engineering
College, Chennai-601206.

INTERNAL EXAMINER EXTERNAL EXAMINER

 AKNOWLEDGEMENT
The success of any project depends largely on the people associated with it. We
are indebted to everyone who has made valuable contribution towards the success of
the project. We would like to take this opportunity to acknowledge the enthusiasm
rendered from all the personalities.
We would express our gratitude to our beloved Chairman Shri. R.S.
MUNIRATHINAM and our Vice-Chairman Shri. R.M. KISHORE, R.M.K. group
of Institutions for having arranged to do this project work.
We are deeply indebted to our Dean Academic Dr. K.
CHANDRASEKARAN, M.E., Ph.D., & our Dean Research Dr.ELWIN
CHANDRA MONIE and our principal Dr. K.A. MOHAMMED JUNAID, M.E.,
Ph.D., for being source of inspiration throughout our study in this college.
We thank our Head of the department Dr. K.R. SENTHIL KUMAR, M.E.,
Ph.D., (IITM) and Faculty member of the department for their guidance and
encouragement at each and every stage of the project work and also guiding us
properly throughout the reviews.
With profound respect, we express our deep sense of gratitude and sincere
thanks to our year coordinator and Project Coordinator Dr.G.Mahendran, M.E.,
Ph.D., internal guide Mr.G.SIVAKKUMAR, M.E., Assistant Professor,
Department of Mechanical Engineering for his valuable guidance and suggestions
throughout this project.
We express our thanks to all non teaching staff members for their kind
assistance and guidance in making the project a grand success.
 ABSTRACT
In this research, the heat transfer performance of fin is analysed by design of fin
with various extensions such as rectangular extension, trapezium extension, triangular
extensions and circular segmental extensions. The heat transfer performance of fin
with same geometry having various extensions and without extensions is compared.
Near about ranging 5% to 13% more heat transfer can be achieved with these various
extensions on fin as compare to same geometry of fin without these extensions. Fin
with various extensions design with the help of SolidWorks 2017 software. Analysis
of fin performance done through the software Ansys Workbench R15.0. In this thermal
analysis, temperature variations with respect to distance at which heat flow occur
through the fin is analysed. Extensions on the finned surfaces is used to increases the
surface area of the fin in contact with the fluid flowing around it. So, as the surface
area increase the more fluid contact to increase the rate of heat transfers from the base
surface as compare to fin without the extensions provided to it. On comparison,
rectangular extensions provide on fin gives the greatest heat transfer than that of other
extensions having the same length and width attached to finned surface. The
effectiveness of fin with rectangular extensions greater as compare to other extensions
on fin.

i
 TABLE OF CONTENTS
CHAPTER TITLE PAGE
NO. NO.
ABSTRACT [1]
LIST OF TABLES [2]

LIST OF FIGURES [7]

LIST OF SYMBOLS [10]

1 INTRODUCTION – HEAT TRANSFER 1
1.1 CONDUCTION 2
1.2 CONVECTION 4
1.3 RADIATION 6
1.4 NEWTON’S LAW OF COOLING 6
2 11
2.1 TYPES OF HEAT TRANSFER 16
2.2 TYPES OF HEAT EXCHANGERS
2.3 DOUBLE PIPE HEAT EXCHANGER
2.4 SHELL AND TUBE HEAT EXCHANGER
2.5 PLATE HEAT EXCHANGER
2.6 PLATE AND SHELL HEAT EXCHANGER
2.7 ADIABATIC WHEEL HEAT EXCHANGER
2.8 PLATE FIN HEAT EXCHANGER
2.9ADVANTAGES OF PLATE AND FIN HEAT
EXCHANGER
2.10 PILLOW PLATE HEAT EXCHANGER
ii
 2.11 FLUID HEAT EXCHANGER
2.12 WASTE HEAT RECOVERY UNITS
2.13 DYNAMIC SCRAPED SURFACE HEAT
EXCHANGER
2.14 PHASE CHANGE HEAT EXCHANGER
2.15 DIRECT CONTACT HEAT EXCHANGER
3 LITERATURE SURVEY 17

4 DESIGN OF FINS SOLID WORKS 23

4.1 MODELLING METHODOLOGY 23
4.2 DESIGN INPUT OF FINS 26
4.3 DESIGN OF 3D MODEL
4.3.1 LONGITUDINAL FINS WITH CIRCULAR
EXTENSIONS
4.3.2 LONGITUDINAL FINS WITH
RECTANGULAR EXTENSIONS
4.3.3 LONGITUDINAL FINS WITH TRIANGULAR
EXTENSIONS
4.3.4 LONGITUDINAL FINS TRAPEZOIDAL
EXTENSIONS
5 THERMAL ANALYSIS OF FINS FOR 27
DIFFERENT CONFIGURATION
5.1 ANSYS WORKBENCH PLATFORM 27
5.2 ANALYSIS OF FINS 28
5.3 CONFIGURATION- 1 CIRCULAR FINS 29
GEOMETRY
5.4 CONFIGURATION- 2 RECTANGULAR FINS
GEOMETRY
iii
 5.5 CONFIGURATION- 3 TRIANGULAR FINS
GEOMETRY
5.6 CONFIGURATION- 4 TRAPEZIUM FINS
GEOMETRY
6 FINS 33
6.1 FINS 33
6.2 ANALYSIS OF FINS WITH UNIFORM CROSS
SECTIONAL AREA
6.3 BOUNDARY CONDITION
6.4 FIN EFFICIENCY

7 MATHEMATICAL CALCULATIONS 42
7.1 FINS WITH CIRCULAR EXTENSIONS
7.2 FINS WITH RECTANGULAR EXTENSIONS
7.3 FINS WITH TRIANGULAR EXTENSIONS
7.4 FINS WITH TRAPEZOIDAL EXTENSIONS
8 CONCLUSION 47

iv
 LIST OF TABLES

TABLE NO. DESCRIPTION PAGE NO.

Table 7.1 COMPARISON OF HEAT TRANSFER IN 48
FINS WITH AND WITHOUT EXTENSIONS

v
 LIST OF FIGURES
FIGURE No. TITLE PAGE No.

Fig.2.1 Hot and cold fluid 5

Fig.2.2 Parallel flow and counter flow heat exchangers 6
Fig.2.3 Hot and cold fluid for parallel flow and counter 6
flow heat exchangers graphical representation
Fig.2.4 Thermal resistance network associated with heat 7
transfer in a double pipe heat exchanger
Fig.4.1 Longitudinal fins with circular extensions 25
Fig.4.2 Longitudinal fins with rectangular extensions 26
Fig.4.3 Longitudinal fins with triangular extensions 26
Fig.4.4 Longitudinal fins with trapezoidal extensions 26
Fig.5.1 Circular fin geometry 29
Fig.5.2 Circular fin geometry with mesh 29
Fig.5.3 Boundary conditions of fins with circular 30
extensions
Fig.5.4 Temperature distributions of fins with circular 30
extensions
Fig.5.5 Total heat flux of fins with circular extensions 31
Fig.5.6 Rectangular fin geometry 31
Fig.5.7 Rectangular fin geometry with mesh 32
Fig.5.8 Boundary condition of fins with rectangular 32
extensions
Fig.5.9 Temperature distribution of fins with rectangular 33
extensions
Fig.5.10 Total heat flux of fins with rectangular extensions 33
Fig.5.11 Triangular fin geometry 34
vi
Fig.5.12 Triangular fin geometry with mesh 34
Fig.5.13 Boundary conditions of fins with triangular extensions 35
Fig.5.14 Temperature distribution of fins with triangular 35
extensions
Fig.5.15 Total heat flux of fins with triangular extensions 36
Fig.5.16 Trapezoidal fin geometry 36
Fig.5.17 Trapezoidal fin geometry with mesh 37
Fig.5.18 Boundary conditions of fins with trapezoidal extensions 37
Fig.5.19 Temperature distribution of fins with trapezoidal 38
extensions
Fig.5.20 Total heat flux of fins with trapezoidal extensions 38
Fig.6.1 Different types of fins 40
Fig.6.2 General diagram of longitudinal fin without extensions 41
for derivations
Fig.6.3 Rectangular fin 41
Fig.6.4 Pin fin 42
Fig.6.5 Fin with tip insulated 44
Fig.6.6 Fins with finite length with end insulated 45
Fig.7.1 Dimensions of circular extensions 48
Fig.7.2 Dimensions of rectangular extensions 50
Fig.7.3 Dimensions of triangular extensions 51
Fig.7.4 Dimensions of trapezoidal extensions 53

vii
 LIST OF SYMBOLS

SYMBOL DEFINITION UNITS

T0 Temperature at base fin K

Tα Room temperature K

K Thermal conductivity W/mK

h Heat transfer coefficient W/m2K

Q Heat transfer J
M Mass G
L Length mm
P Perimeter mm
A Area mm2

viii
 CHAPTER 1
INTRODUCTION - HEAT TRANSFER

Heat energy can be transferred from one body to the other or from one
location in a body to the other. Study of the techniques and methods adopted to transfer
heat energy is known as ‘Heat Transfer’. To facilitate heat transfer between 2 bodies
there needs to be a temperature difference between them. This means that these bodies
must be a 2 different temperatures one higher than the other to allow heat to flow from
one body to the other.

This means that no heat transfer occurs between 2 bodies which are at the
same temperature. At the same time, it is very important to note that heat only flows
from a body at higher temperature to a body at a lower temperature. Although this may
look obvious, this law is very important from the point of view of thermodynamics.

There are three types of heat transfer

1.1 Conduction

Conduction is the method of transfer of heat within a body or from one body to the
other due to the transfer of heat by molecules vibrating at their mean positions. The
bodies through which the heat transfer must be in contact with each other. There is no
actual movement of matter while transferring heat from one location to the other.

Conduction occurs usually in solids where molecules in the structure are held together
strongly by intermolecular forces of attraction amongst them and so they only vibrate
about their mean positions as they receive heat energy and thus pass it to the
surrounding molecules by vibrations.

1
1.2 Convection

Convection is the mode of heat transfer which occurs mostly in liquids and gases.In
this method, heat transfer takes place with the actual motion of matter from one place
within the body to the other. Often when we boil water we have seen bubbles and
currents develop in the water on careful observation.

This is an apt example of the convection process. The hot water at the bottom becomes
lighter and moves upwards forcing the cold and denser water at the top to come down
and thus get heated up.

1.3 Radiation

Radiation is another form of heat transfer. It does not require any medium and can be
used for transfer of heat in a vacuum as well. This method uses electromagnetic waves
which transfer heat from one place to the other. The heat and light from the sun in our
solar system reach our planet using radiation only.

In fact, radiation is the most potent method of heat transfer. In winters when we sit near
a fire we feel warm without actually touching the burning wood. This is possible by
radiation only.

1.4 Newton’s Law of cooling

Newton’s law of Cooling states that there is always a direct correlation between the rate
of change of temperature of a body and the temperature difference between the object
and the surroundings. What this simply means is a hot body will cool down faster if the
temperature of the body is much greater than that of the ambient. Whereas another

2
body which has a temperature that is closer to the ambient temperature will take a little
more time.

They are widely used in space heating, refrigeration, air conditioning, power plants,
chemical plants, petrochemical plants, petroleum refineries, natural gas processing,
and sewage treatment. The classic example of a heat exchanger is found in an internal
combustion engine in which a circulating fluid known as engine coolant flows through
radiator coils and air flows past the coils, which cools the coolant and heats the
incoming air.

3
 CHAPTER-2
2.1 HEAT EXCHANGER:
A heat exchanger is a piece of equipment built for efficient heat transfer from
one medium to another. The media may be separated by a solid wall to prevent mixing
or they may be in direct contact.
Heat exchangers are devices that facilitate the exchange of heat between two
fluids that are at different temperatures while keeping them from mixing with each
other. Heat exchangers are commonly used in practice in a wide range of applications,
from heating and air-conditioning systems in a household, to chemical processing and
power production in large plants. Heat exchangers differ from mixing chambers in
that they do not allow the two fluids involved to mix. In a car radiator, for example,
heat is transferred from the hot water flowing through the radiator tubes to the air
flowing through the closely spaced thin plates outside attached to the tubes.
Heat transfer in a heat exchanger usually involves convection in each fluid and
conduction through the wall separating the two fluids.
In the analysis of heat exchangers, it is convenient to work with an overall heat
transfer coefficient U that accounts for the contribution of all these effects on heat
transfer. The rate of heat transfer between the two fluids at a location in a heat
exchanger depends on the magnitude of the temperature difference at that location,
which varies along the heat exchanger. In the analysis of heat exchangers, it is usually
convenient to work with the logarithmic mean temperature difference LMTD, which
is an equivalent mean temperature difference between the two fluids for the entire heat
exchanger.

4
 Fig 2.1 Hot and Cold Fluid
2.2 TYPES OF HEAT EXCHANGERS
Different heat transfer applications require different types of hardware and
different configurations of heat transfer equipment. The attempt to match the heat
transfer hardware to the heat transfer requirements within the specified constraints has
resulted in numerous types of innovative heat exchanger designs. The simplest type of
heat exchanger consists of two concentric pipes of different diameters, called the
double-pipe heat exchanger. One fluid in a double-pipe heat exchanger flows through
the smaller pipe while the other fluid flows through the annular space between the two
pipes.
Two types of flow arrangement are possible in a double-pipe heat exchanger: in
parallel flow, both the hot and cold fluids enter the heat exchanger at the same end and
move in the same direction. In counter flow, on the other hand, the hot and cold fluids
enter the heat exchanger at opposite ends and flow in opposite directions.
Two General types of Heat Exchangers:
• Parallel Flow Heat Exchanger
• Counter Flow Heat Exchanger

5
Fig 2.2 Parallel flow and counter flow heat exchanger

Fig 2.3 Hot and Cold Fluid for parallel flow and counter flow heat exchangers,
Graphical representations
A heat exchanger typically involves two flowing fluids separated by a solid
wall. Heat is first transferred from the hot fluid to the wall by convection, through the
wall by conduction, and from the wall to the cold fluid again by convection. Any
radiation effects are usually included in the convection heat transfer coefficients. The
thermal resistance network associated with this heat transfer process involves two
convection and one conduction resistances, as shown in Figure below.

6
 Fig 2.4 Thermal resistance network associated with heat transfer in a double-pipe
heat exchanger.
2.3 DOUBLE PIPE HEAT EXCHANGER
Double pipe heat exchangers are the simplest exchangers used in industries. On
one hand, these heat exchangers are cheap for both design and maintenance, making
them a good choice for small industries. But on the other hand, low efficiency of them
beside high space occupied for such exchangers in large scales, has led modern
industries to use more efficient heat exchanger like shell and tube or other ones. But
yet, since double pipe heat exchangers are simple, they are used to teach heat
exchanger design basic to students and as the basic rules for modern and normal heat
exchangers are the same, students can understand the design techniques much easier.
To start the design of a double pipe heat exchanger, the first step is to calculate
the heat duty of the heat exchanger. It must be noted that for easier design, it’s better
to ignore heat loss in heat exchanger for primary design. The heat duty can be defined
as the heat gained by cold fluid which is equal to the heat loss of the hot fluid.
7
2.4 SHELL AND TUBE HEAT EXCHANGER
Shell and tube heat exchangers consist of a series of tubes. One set of these tubes
contains the fluid that must be either heated or cooled. The second fluid runs over the
tubes that are being heated or cooled so that it can either provide the heat or absorb the
heat required.
A set of tubes is called the tube bundle and can be made up of several types of
tubes: plain, longitudinally finned, etc. Shell and tube heat exchangers are typically
used for high-pressure applications (with pressures greater than 30 bar and
temperatures greater than 260 °C).
This is because the shell and tube heat exchangers are robust due to their shape.
Several thermal design features must be considered when designing the tubes in the
shell and tube heat exchangers:
Tube diameter: Using a small tube diameter makes the heat exchanger both
economical and compact. However, it is more likely for the heat exchanger to foul up
faster and the small size makes mechanical cleaning of the fouling difficult. To prevail
over the fouling and cleaning problems, larger tube diameters can be used. Thus to
determine the tube diameter, the available space, cost and the fouling nature of the
fluids must be considered.
Tube thickness: The thickness of the wall of the tubes is usually determined to ensure:
There is enough room for corrosion.
That flow-induced vibration has resistance.
Axial strength.
Availability of spare parts.
Hoop strength (to withstand internal tube pressure).
Buckling strength (to withstand overpressure in the shell).
Tube length: heat exchangers are usually cheaper when they have a smaller shell
diameter and a long tube length. Thus, typically there is an aim to make the heat
exchanger as long as physically possible whilst not exceeding production capabilities.
8
However, there are many limitations for this, including space available at the
installation site and the need to ensure tubes are available in lengths that are twice the
required length (so they can be withdrawn and replaced). Also, long, thin tubes are
difficult to take out and replace.
Tube pitch: when designing the tubes, it is practical to ensure that the tube pitch (i.e.,
the centre-centre distance of adjoining tubes) is not less than 1.25 times the tubes'
outside diameter. A larger tube pitch leads to a larger overall shell diameter, which
leads to a more expensive heat exchanger.
Tube corrugation: this type of tubes, mainly used for the inner tubes, increases the
turbulence of the fluids and the effect is very important in the heat transfer giving a
better performance.
Tube Layout: refers to how tubes are positioned within the shell. There are four main
types of tube layout, which are, triangular (30°), rotated triangular (60°), square (90°)
and rotated square (45°). The triangular patterns are employed to give greater heat
transfer as they force the fluid to flow in a more turbulent fashion around the piping.
Square patterns are employed where high fouling is experienced and cleaning is more
regular.
Baffle Design: baffles are used in shell and tube heat exchangers to direct fluid across
the tube bundle. They run perpendicularly to the shell and hold the bundle, preventing
the tubes from sagging over a long length. They can also prevent the tubes from
vibrating. The most common type of baffle is the segmental baffle. The semicircular
segmental baffles are oriented at 180 degrees to the adjacent baffles forcing the fluid
to flow upward and downwards between the tube bundle. Baffle spacing is of large
thermodynamic concern when designing shell and tube heat exchangers. Baffles must
be spaced with consideration for the conversion of pressure drop and heat transfer. For
thermo economic optimization it is suggested that the baffles be spaced no closer than
20% of the shell’s inner diameter. Having baffles spaced too closely causes a greater
pressure drop because of flow redirection. Consequently having the baffles spaced too
9
far apart means that there may be cooler spots in the corners between baffles. It is also
important to ensure the baffles are spaced close enough that the tubes do not sag. The
other main type of baffle is the disc and donut baffle, which consists of two concentric
baffles. An outer, wider baffle looks like a donut, whilst the inner baffle is shaped like
a disk. This type of baffle forces the fluid to pass around each side of the disk then
through the donut baffle generating a different type of fluid flow.
Fixed tube liquid-cooled heat exchangers especially suitable for marine and
harsh applications can be assembled with brass shells, copper tubes, brass baffles, and
forged brass integral end hubs.
2.5 PLATE HEAT EXCHANGER
Another type of heat exchanger is the plate heat exchanger. One is composed of
multiple, thin, slightly separated plates that have very large surface areas and fluid
flow passages for heat transfer. This stacked-plate arrangement can be more effective,
in a given space, than the shell and tube heat exchanger. Advances in gasket and
brazing technology have made the plate-type heat exchanger increasingly practical. In
HVAC applications, large heat exchangers of this type are called plate-and-frame;
when used in open loops, these heat exchangers are normally of the gasket type to
allow periodic disassembly, cleaning, and inspection.
There are many types of permanently bonded plate heat exchangers, such as dip-
brazed, vacuum-brazed, and welded plate varieties, and they are often specified for
closed-loop applications such as refrigeration. Plate heat exchangers also differ in the
types of plates that are used, and in the configurations of those plates. Some plates
may be stamped with "chevron", dimpled, or other patterns, where others may have
machined fins and/or grooves.
2.6 PLATE AND SHELL HEAT EXCHANGER
A third type of heat exchanger is a plate and shell heat exchanger, which
combines plate heat exchanger with shell and tube heat exchanger technologies. The
heart of the heat exchanger contains a fully welded circular plate pack made by
10
pressing and cutting round plates and welding them together. Nozzles carry flow in
and out of the plate pack (the 'Plate side' flow path).The fully welded plate pack is
assembled into an outer shell that creates a second flow path ( the 'Shell side'). Plate
and shell technology offers high heat transfer, high pressure, and high operating
temperature, compact size, low fouling and close approach temperature. In particular,
it does completely without gaskets, which provides security against leakage at high
pressures and temperatures.
2.7 ADIABATIC WHEEL HEAT EXCHANGER
A fourth type of heat exchanger uses an intermediate fluid or solid store to hold
heat, which is then moved to the other side of the heat exchanger to be released. Two
examples of this are adiabatic wheels, which consist of a large wheel with fine threads
rotating through the hot and cold fluids, and fluid heat exchangers.

2.8 PLATE FIN HEAT EXCHANGER

This type of heat exchanger uses "sandwiched" passages containing fins to
increase the effectiveness of the unit. The designs include cross flow and counter flow
coupled with various fin configurations such as straight fins, offset fins and wavy fins.
Plate and fin heat exchangers are usually made of aluminum alloys, which
provide high heat transfer efficiency. The material enables the system to operate at a
lower temperature and reduce the weight of the equipment.
Plate and fin heat exchangers are mostly used for low temperature services such
as natural gas, helium and oxygen liquefaction plants, air separation plants and
transport industries such as motor and aircraft engines.
2.9 ADVANTAGES OF PLATE AND FIN HEAT EXCHANGERS:
High heat transfer efficiency especially in gas treatment larger heat transfer area
Approximately 5 times lighter in weight than that of shell and tube heat exchanger.
2.10 PILLOW PLATE HEAT EXCHANGER:
A pillow plate exchanger is commonly used in the dairy industry for cooling
11
milk in large direct-expansion stainless steel bulk tanks. The pillow plate allows for
cooling across nearly the entire surface area of the tank, without gaps that would occur
between pipes welded to the exterior of the tank.
The pillow plate is constructed using a thin sheet of metal spot-welded to the
surface of another thicker sheet of metal. The thin plate is welded in a regular pattern
of dots or with a serpentine pattern of weld lines. After welding the enclosed space is
pressurized with sufficient force to cause the thin metal to bulge out around the welds,
providing a space for heat exchanger liquids to flow, and creating a characteristic
appearance of a swelled pillow formed out of metal.
2.11 FLUID HEAT EXCHANGERS:
This is a heat exchanger with a gas passing upwards through a shower of fluid
(often water), and the fluid is then taken elsewhere before being cooled. This is
commonly used for cooling gases whilst also removing certain impurities, thus solving
two problems at once.
It is widely used in espresso machines as an energy-saving method of cooling
super-heated water to use in the extraction of espresso.
2.12 Waste Heat Recovery Units
A Waste Heat Recovery Unit (WHRU) is a heat exchanger that recovers heat
from a hot gas stream while transferring it to a working medium, typically water or
oils. The hot gas stream can be the exhaust gas from a gas turbine or a diesel engine
or a waste gas from industry or refinery.
Big systems with high volume and temperature gas stream, typical on industry,
can benefit from Steam Rankin Cycle (SRC) in a WHRU, but small systems become
too expensive to use it. The recovery of heat from low temperature systems requires
more efficient working fluids than steam.
An Organic Rankin Cycle (ORC) WHRU can be more efficient at low
temperature range using Refrigerant that boil at lower temperatures then water.
Typical organic refrigerants are Ammonia, Pentafluoropropane(R-245fa and R-
12
245ca), and Toluene.
The refrigerant is boiled by the heat source in the Evaporator to produce super-
heated vapor. This fluid is expanded in the turbine to convert thermal energy to kinetic
energy that is converted to electricity in the electrical generator. This energy transfer
process decreases the temperature of the refrigerant that, in turn, condenses. The cycle
is closed and completed using a pump to send the fluid back to the evaporator.
2.13 DYNAMIC SCRAPED SURFACE HEAT EXCHANGER:
Another type of heat exchanger is called "(dynamic) scraped surface heat
exchanger". This is mainly used for heating or cooling with high-viscosity products,
crystallization processes, evaporation and high-fouling applications. Long running
times are achieved due to the continuous scraping of the surface, thus avoiding fouling
and achieving a sustainable heat transfer rate during the process.
2.14 PHASE-CHANGE HEAT EXCHANGERS
Typical water-cooled surface condenser
In addition to heating up or cooling down fluids in just a single phase, heat
exchangers can be used either to heat a liquid to evaporate (or boil) it or used as
condensers to cool a vapor and condense it to a liquid. In chemical plants and
refineries, reboilers used to heat incoming feed for distillation towers are often heat
exchangers. Distillation set-ups typically use condensers to condense distillate vapors
back into liquid.
Power plants that use steam-driven turbines commonly use heat exchangers to
boil water into steam. Heat exchangers or similar units for producing steam from water
are often called boilers or steam generators.
In the nuclear power plants called pressurized water reactors, special large heat
exchangers pass heat from the primary (reactor plant) system to the secondary (steam
plant) system, producing steam from water in the process. These are called steam
generators. All fossil-fueled and nuclear power plants using steam-driven turbines
have surface condensers to convert the exhaust steam from the turbines into
13
condensate (water) for re-use.
To conserve energy and cooling capacity in chemical and other plants,
regenerative heat exchangers can transfer heat from a stream that must be cooled to
another stream that must be heated, such as distillate cooling and reboilers feed pre-
heating.
This term can also refer to heat exchangers that contain a material within their
structure that has a change of phase. This is usually a solid to liquid phase due to the
small volume difference between these states.
This change of phase effectively acts as a buffer because it occurs at a constant
temperature but still allows for the heat exchanger to accept additional heat. One
example where this has been investigated is for use in high power aircraft electronics.
Heat exchangers functioning in multiphase flow regimes may be subject to the Leading
instability.
2.15 DIRECT CONTACT HEAT EXCHANGERS
Direct contact heat exchangers involve heat transfer between hot and cold streams of
two phases in the absence of a separating wall. Thus such heat exchangers can be
classified as:
• Gas – liquid
• Immiscible liquid – liquid
• Solid-liquid or solid – gas

Most direct contact heat exchangers fall under the Gas – Liquid category, where heat
is transferred between a gas and liquid in the form of drops, films or sprays. Such types
of heat exchangers are used predominantly in air conditioning, humidification,
industrial hot water heating, and water cooling, condensing plants.

14
 CHAPTER 3
LITERATURE REVIEW
Charan et. al. (2018) analyzed extended surfaces, which are
commonly used to enhance convection heat transfer in a wide range of engineering
applications. The conception of introducing perforations on the lateral surface of fin is
to enhance heat transfer rate effectively. From the research, it is evident that tip
temperature is minimum for aluminum triangularly perforated with three perforations
in it and heat transfer is maximum for triangularly perforated with three perforations
of aluminum material. From research study, it shows that Nusselt number increases
for perforated fin when compared with non- perforated fin. Therefore it is concluded
that a three triangle laterally perforated aluminum is most suitable for the fin
applications.
Sangaj et. al. (2018) experimentally found out the temperature
distribution within the pin fin made of different material and geometries and performed
steady state heat transfer analysis using a finite element software ANSYS to test and
validate results. The main aim of the work is to optimize the thermal properties by
varying geometry, material and thickness of fins. The present work is successfully
carried out by comparing various parameters (shape, geometry, material) of pin-fin.
The different types of shape and material have been chosen for the comparison.
Analysis has been carried out in ANSYS. From above two cases it is found that copper
circular hollow pin-fin and copper rectangular pin-fin are the most optimum pin-fins.
Beldar et. al. (2017) performed steady thermal analysis by using CFD
software. Air Flow analysis, pressure drop analysis had performed. The notch size
is varying from 10%, 20% and 30% the heat input is varying from 25 watt, 45 watt
and 65 watt. In area not compensated fin array though area of fin will decrease still
heat transfer increase. with compensation fin array the central material of fin is
exposed to fresh cold air again it is found that heat transfer is
increasing. After provision of notch at the central portion of fin leads to change of flow
15
pattern of natural air, increase in the air velocity across channel, Variation of air
pressure across channel and increase of air temperature in cylindrical
heat sink.
Rajesh et. al. (2017) analysed the thermal properties by varying
geometry, material (Cu and Al alloy 6082), distance between the fins and thickness of
cylinder fins. The Fins models are created by varying the geometry circular and also
by varying thickness of the fins for both geometries. The 3D modelling software
Pro/Engineer and Unigraphics were used. Thermal analysis was done on the cylinder
fins to determine variation temperature distribution over time. The analysis was done
using ANSYS. By doing thermal analysis on the engine cylinder fins, it has been
concluded that it is helpful to know the heat dissipation inside the cylinder.
Jain et. al. (2017) analysed the thermal heat dissipation of fins by
varying its geometry. Parametric models of fins have been developed to predict the
transient thermal behaviour. There after models were created by varying the geometry
such as rectangular, circular, triangular and fins with extension. The modelling
software CREO Parametric 2.0 has been used.
The analysis has been done using ANSYS 14.5. It is discussed that presently material
which is used for manufacturing fin body is generally Aluminium Alloy 204 which
has thermal conductivity of 110-150W/m-⁰C. After determining the
material, the third step is to increase the heat transfer rate of the system by varying
geometrical parameters such as cross sectional area, parameter, length, thickness, etc.
which ultimately leads us to fins of varying shape and geometries.
Kummitha et. al. (2017) studied thermal analysis of cylinder block.
The thermal analyses were performed with various alloys to find out the best material
which gave the best heat transfer rate through it and kept the engine in safe working
condition and also had high strength with light weight. For this study, passion pro bike
cylinder block was considered and modelled by using GAMBIT software and also
thermal analyses were performed by using ANSYS software. Hence in this study,
16
some of aluminium alloys are also considered for thermal analysis and compared all
the results for best one. it is to be concluded that A380 had the better heat transfer rate
along with more strength as compared with other considered alloys.
Ravikumar et. al. (2017) discussed about the geometric variables
and design of heat sink for enhancing the thermal performance is experimented. This
project makes use of thermal evaluation to perceive a cooling answer for a computer
pc, which uses a 5 W CPU. The design was able to cool the chassis with heat sink
joined to the CPU which was adequate to cool the whole machine. This work
considered the round cylindrical pin fins and square plate heat sink fins layout with
aluminium base plate and the control of CPU heat sink procedures. An opportunity
model of heat fins has been designed to increase heat dissipation. In ANSYS, the
proposed substance has been analysed and the consequences of regular state and
transient thermal evaluation are taken for comparison.

Sandeep Kumar et. al. (2017) Studied heat transfer rate from the
heating zone in IC engine, for that transient thermal analysis have been performed on
actual design of Bajaj discover 125 CC single cylinder engine. Transient thermal
analyses were performed for actual and proposed design of engine cylinder in order to
optimize geometrical parameters and enhanced heat transfer from the IC engine.
Result revel that the proposed design of IC engine has better performance and
heat transfer rate from the heating zone in the IC engine that is why the result of present
work are found to be more concentrated on it and also proposed replacement of new
design. Transient thermal analysis has been
performed on actual design and also on two different geometrical designs at ambient
temperature of 25 0C.
Arefin (2016) introduced modified pin design for pin fin heat sink
where the pins have been expanded outward. After that, thermal analysis of the
conventional pin fin heat sink and the modified pin fin heat sink has been conducted
17
numerically for natural convection for circular shape in inline arrangement
assuming steady state condition. The modified pin fin heat sink has been observed
to perform better than the conventional ones. For this numerical thermal
analysis has been used with the help of Solidworks. The proposed model of the
modified pin fin heat sink has been created in a virtual environment. The conventional
model of pin fin heat sink was also created in the same environment
for comparison. Thermal analysis of the conventional model and the modified model
was conducted and compared successfully.
Balendra et. al. (2016) performed experimental analysis and
simulation for rectangular unnotched fin and validated it
for different thermal loads. After that the authors worked for different forms of
constant area as an inverted notched fin. All above result of the distribution of
temperature, velocity vector plot, Nusselt number and the heat transfer coefficient, it
was concluded that the heat transfer coefficient increased continuously in all cases but
inverted triangular notched fin gave maximum heat transfer rate. Inverted trapezoidal
notched fin gave 6.08 W/m2°k heat transfer coefficient which was better than inverted
rectangular notched fin which give 5.67 W/m2°k heat transfer. As per the result, it is
concluded that heat transfer rate of inverted triangular notched fin has been
increased by almost 50.51% as compared to rectangular unnotched fin.
Kongre et. al. (2016) analyzed the temperature distribution by
varying geometry and thickness of cylinder fins using ANSYS workbench. By doing
experimental work on array of perforated fins of solid Vs square & circular perforation
it is observed that; Nusselt number of solid as well as perforated fins increase with
increase in Reynolds number. Also for same size of perforations square perforations
give slight higher percentage of effectiveness improvement in square holes than
circular. Thus the authors concluded that even though the attempts have been
made to modify several parameters related to fin for HT augmentation, but still there
is a vast scope for fin design modification.
18
 L. Natrayan et. al. (2016) analysed the thermal properties by
varying geometry of cylinder fins using ANSYS workbench. The 3D model of the
geometries has been created using SOLIDWORKS 2016 and its thermal properties
have been analysed using ANSYS workbench 2016. The variation of temperature
distribution over time is of interest in many applications such as in cooling. The
accurate thermal simulation could permit critical design parameters to be identified
for improved life. Presently Material used for manufacturing cylinder fin body is
Aluminium Alloy AA 6061 which has thermal conductivity of 160 – 170 W/mk.

19
 CHAPTER 4
DESIGN OF FINS SOLIDWORKS
SolidWorks is a 3D mechanical CAD (computer-aided design) program that
runs on Microsoft Windows and is being developed by Dassault Systèmes SolidWorks
Corp., a subsidiary of Dassault Systèmes, S. A. (Vélizy, France). SolidWorks is
currently used by over 2 million engineers and designers at more than 165,000
companies worldwide. FY2011 revenue for SolidWorks was 483 million dollars.
4.1 MODELING METHODOLOGY
SolidWorks is a Parasolid-based solid modeler, and utilizes a parametric
feature-based approach to create models and assemblies. Parameters refer to
constraints whose values determine the shape or geometry of the model or assembly.
Parameters can be either numeric parameters, such as line lengths or circle diameters,
or geometric parameters, such as tangent, parallel, concentric, horizontal or vertical,
etc. Numeric parameters can be associated with each other through the use of relations,
which allows them to capture design intent.
Design intent is how the creator of the part wants it to respond to changes and
updates. For example, you would want the hole at the top of a beverage can to stay at
the top surface, regardless of the height or size of the can.
SolidWorks allows the user to specify that the hole is a feature on the top
surface, and will then honor their design intent no matter what height they later assign
to the can.
Features refer to the building blocks of the part. They are the shapes and
operations that construct the part. Shape-based features typically begin with a 2D or
3D sketch of shapes such as bosses, holes, slots, etc. This shape is then extruded or cut
to add or remove material from the part. Operation-based features are not sketch-
based, and include features such as fillets, chamfers, shells, applying draft to the faces
of a part, etc.
Building a model in SolidWorks usually starts with a 2D sketch (although 3D
20
sketches are available for power users). The sketch consists of geometry such as points,
lines, arcs, conics (except the hyperbola), and splines. Dimensions are added to the
sketch to define the size and location of the geometry. Relations are used to define
attributes such as tangency, parallelism, perpendicularity, and concentricity. The
parametric nature of SolidWorks means that the dimensions and relations drive the
geometry, not the other way around. The dimensions in the sketch can be controlled
independently, or by relationships to other parameters inside or outside of the sketch.
In an assembly, the analog to sketch relations are mates. Just as sketch relations
define conditions such as tangency, parallelism, and concentricity with respect to
sketch geometry, assembly mates define equivalent relations with respect to the
individual parts or components, allowing the easy construction of assemblies.
SolidWorks also includes additional advanced mating features such as gear and cam
follower mates, which allow modeled gear assemblies to accurately reproduce the
rotational movement of an actual gear train.
Finally, drawings can be created either from parts or assemblies. Views are
automatically generated from the solid model, and notes, dimensions and tolerances
can then be easily added to the drawing as needed. The drawing module includes most
paper sizes and standards (ANSI, ISO, DIN, GOST, JIS, BSI and SAC).
4.2 DESIGN INPUT OF FINS :
The fin with various extensions are design with the help of design software Solidworks
by using the 2D and 3D commands like as 2D commands Sketching, arc, mirror,
Extrude ,3D commands extrude. The line draws with the Polar mode. In this mode
length of the line and angle of the line is defined to draw the design.
The angle is measured in anti-clock direction starting from the first quadrant.
Main Fin specifications:
Length, l = 50mm = 0.05 m,
Width, b = 300 mm = 0.30 m
Thickness, y = 15mm = 0.015 m.
21
4.3 DESIGN OF 3D MODEL
Design Fins: 3D Design in Solidworks Graphics user Interface
4.3.1 LONGITUDINAL FINS WITH CIRCULAR EXTENSIONS:

Fig 4.1 Longitudinal fins with circular extensions

4.3.2 LONGITUDINAL FINS WITH RECTANGULAR EXTENSIONS:

Fig 4.2 Longitudinal fins with rectangular extensions

22
4.3.3 LONGITUDINAL FINS WITH TRIANGULAR EXTENSIONS:

Fig 4.3 Longitudinal fins with triangular extensions

LONGITUDINAL FINS WITH TRAPEZIUM EXTENSIONS:

Fig 4.4 Longitudinal fins with trapezoidal extensions

23
 CHAPTER 5
THERMAL ANALYSIS OF FINS FOR DIFFERENT CONFIGURATIONS
ANSYS is an engineering simulation software (computer-aided engineering, or
CAE) developer that is headquartered south of Pittsburgh in the South pointe business
park in Cecil Township, Pennsylvania, and United States.
ANSYS was listed on the NASDAQ stock exchange in 1996. In late 2011,
ANSYS received the highest possible score on its Smart Select Composite Ratings
according to Investor's Business Daily. The organization reinvests 15 percent of its
revenues each year into research to continually refine the software.
ANSYS offers engineering simulation solution sets in engineering simulation
that a design process requires. Companies in a wide variety of industries use ANSYS
software. The tools put a virtual product through a rigorous testing procedure (such as
crashing a car into a brick wall, or running for several years on a tarmac road) before
it becomes a physical object.

5.1 ANSYS Workbench Platform:

The ANSYS Workbench platform is the framework upon which the industry’s
24
broadest and deepest suite of advanced engineering simulation technology is built. An
innovative project schematic view ties together the entire simulation process, guiding
the user through even complex multiphysics analyses with drag-and-drop simplicity.
With bidirectional CAD connectivity, powerful highly-automated meshing, a project-
level update mechanism, pervasive parameter management and integrated
optimization tools, the ANSYS Workbench platform delivers unprecedented
productivity, enabling Simulation-Driven Product Development.
5.2 ANALYSIS OF FINS:
In this assign the material having thermal conductivity, convection coefficient of heat
transfer for fluid, temperature of surface and ambient temperature as:
Thermal conductivity, k = 40 W/m °C = 0.04 J/(s mm °C)
Convection coefficient of heat transfer, h = 40 W/m2 °C = 0.00004 J/(s mm2 °C)
Temperature of wall surface at which fin attached, to = 55 °C Ambient temperature,
ta = 30 °C

25
5.3 CONFIGURATION -1: CIRCULAR FINS GEOMETRY:

Fig 5.1 Circular fin Geometry

MESH:

Fig5.2 Circular Fin geometry with mesh

BOUNDARY CONDITIONS:

26
 Fig 5.3 Boundary conditions of fins with circular extensions
TEMPERATURE DISTRIBUTIONS:

Fig 5.4 Temperature distributions of fins with circular extensions

TOTAL HEAT FLUX:

27
 Fig 5.5 Total heat flux of fins with circular extensions
CONFIGURATION -2: RECTANGULAR FINS GEOMETRY:

Fig 5.6 Rectangular fin Geometry

MESH:

28
 Fig 5.7 Rectangular Fin geometry with mesh
BOUNDARY CONDITIONS:

Fig 5.8 Boundary conditions of fins with rectangular extensions

TEMPERATURE DISTRIBUTIONS:

29
Fig 5.9 Temperature distributions of fins with rectangular extensions
TOTAL HEAT FLUX:

Fig 5.10 Total heat flux of fins with rectangular extensions

30
CONFIGURATION -3: TRIANGULAR FINS GEOMETRY:

Fig 5.11 Triangular fin Geometry

MESH:

e
Fig5.12 Triangular Fin geometry with mesh

31
BOUNDARY CONDITIONS:

Fig 5.13 Boundary conditions of fins with traingular extensions

TEMPERATURE DISTRIBUTIONS:

Fig 5.14 Temperature distributions of fins with triangular extensions

TOTAL HEAT FLUX:

32
Fig 5.15 Total heat flux of fins with triangular extensions
CONFIGURATION -4: TRAPEZIUMM FINS GEOMETRY:

Fig 5.16 Circular fin Geometry

33
MESH:

Fig5.17 Trapezoidal Fin geometry with mesh

BOUNDARY CONDITIONS:

Fig 5.18 Boundary conditions of fins with trapezoidal extensions

34
TEMPERATURE DISTRIBUTIONS:

Fig 5.4
Fig 5.19 Temperature distributions of fins with trapezoidal extensions
TOTAL HEAT FLUX:

Fig 5.20 Total heat flux of fins with trapezoidal extensions

35
 CHAPTER -6
FINS

Convection heat transfer between a hot solid surface and the

surrounding colder fluid is governed by the Newton’s cooling law which states that
“the rate of convection heat transfer is directly proportional to the temperature
difference between the hot surface and the surrounding fluid and is also directly
proportional to the area of contact or exposure between them”. Newton’s law of
cooling can be expressed as

Qconv = h A (Ts -T∞)

Where, h = convection heat transfer coefficient

Ts = Hot surface temperature

T∞= Fluid temperature

A = area of contact or exposure

Therefore, convection heat transfer can be increased by either of the following ways-
1. Increasing the temperature difference (T s ) between the surface and the fluid.

2. Increasing the convection heat transfer coefficient by enhancing the fluid flow or
flow velocity over the body.
3. Increasing the area of contact or exposure between the surface and the fluid.

Most of the times, to control the temperature difference is not feasible and increase
of heat transfer coefficient may require installation of a pump or a fan or replacing
the existing one with a new one having higher capacity, the alternative is to increase
the effective surface area by extended surfaces or fins.

Fins are the extended surface protruding from a surface or body and they are meant
for increasing the heat transfer rate between the surface and the surrounding fluid by
increasing heat transfer area.

36
Example of surfaces where fins are used

1. Air cooled I.C. engines

2. Refrigeration condenser tubes
3. Electric transformers
4. Reciprocating air compressors
5. Semiconductor devices
6. Automobile radiator

6.1 Types of fin

Fins can be broadly classified as:
1. Longitudinal fin

2. Radial fin

3. Pin fin

Fig 6.1 Different types of fins

(a) Longitudinal fin – Rectangular profile
(b) Longitudinal fin – Rectangular profile
(c) Longitudinal fin - Trapezoidal profile

37
(d) Longitudinal fin - Concave parabolic
(e) Radial fin – Rectangular profile
(f) Radial fin – Triangular profile
(g) Pin fin – Cylindrical
(h) Pin fin – Tapered profile
(i) Pin fin – Concave parabolic

Fig 6.2 General diagram of longitudinal fin without extensions for derivations
6.2 Analysis of fins with uniform cross sectional area

Fig 6.3 Rectangular fin

38
To = base temperature or root temperature

Heat is conducted from the base in to the fin at its root and then while
simultaneously conducting along the length of the fin, heat is also convected from
the surface of the fin to the ambient fluid with the convective heat transfer
coefficient of h in W/m2Kelvin.

Consider a differential element of the fin of length dx. Let Q x is the heat conducted
in to the element along x- direction given by
Q=kA(dT/dx) Fourier law of conduction
Where
k = thermal conductivity of fin material
Ac= Area of cross section of the fin
h=Heat transfer coefficient

This is a standard format of 2nd order differential equation in whose general

solution can be given as

Ɵ= C1 e –mx + C2 emx
Where m = √hp/√kA c
And C1 and C2 are constant of integration that are to be obtained from boundary
conditions.

Fig 6.4 Pin fin

39
6.3 Boundary conditions:
(a) One common boundary condition is
At x = 0 (root), T = To and Ɵ = Ɵ0 = To - T∞
The other boundary condition i.e. at the tip depends upon three different cases
which are as follows:
Case -1: Fin is infinitely long (very long fin)
When the fin is infinitely long then the temperature at the tip of the fin
will be essentially that of the fluid.
At x = 0, Ɵ= T -T∞ = 0
The general solution is of the form

Ɵ= C 1 e –mx + C 2 emx

when C1=0

Y= C 2 emx

On applying boundary condition at root (x=0), we get temperature distribution

along fin as

T = (To -T∞ ) e –mx +T∞

The heat transfer through fin is:
Qfin= -kAc (Dt/dx)
= √(hPkAc)(To -T∞ )

Case -2: Fin tip is insulated

40
 Fig 6.4 Fin with tip insulated
When the fin tip is insulated then Conduction heat transfer at x = L is equal to zero
i.e. (-kA(dt/dx) )x = L = 0
Hence, boundary condition will be
(dt/dx)x=L = 0 and (dƟ/dx )x=L = 0
The temperature distribution along the length of the fin is given by:

Ɵ/ƟO = T-T∞/TO-T∞ = cosh(m(Lc -x)/cosh(mLc)

The resulting heat transfer rate through the fin will be

Qfin = -kAc (dT/dx )x=0 =√(hPkA) Ɵ0 tan h(mLc)

Case -3: Fin is finite in length and also loses heat by convection from its tip
(End not insulated)

41
 Fig 6.5 Fins with finite length with end insulated
Conduction heat transfer at x = L is equal to convection heat transfer from tip i.e.
(-kA(dT/dx) )x = L = h(Aconv) {T(x=L) -T∞ }

Then the temperature distribution is given by

Ɵ/Ɵ0 = T-T∞/T0 -T∞ =cosh[m(Lc-x)/cosh(mLc)

and Heat transfer rate through fin is

Qfin = √(hPkAc)Ɵ0 tanh(mLc)

Where Lc = Corrected length
Corrected fin length Lc is defined such that heat transfer from a fin of length L c with
insulated tip is equal to heat transfer from the actual fin of length L with convection
at the fin tip.

For longitudinal fin (rectangular), L c = L +t/2

For pin fin (cylindrical), Lc = L + t/2

6.4 Fin Efficiency

It is defined as the ratio of actual heat transfer rate taking place through the fin and
the entire fin is at its root temperature or base temperature.
The entire fin will be at its root temperature only when the material of the fin has
42
infinite thermal conductivity.

η long fin =Qact/Qmax possible

=√(hPkA)Ɵ0 tanh(mL)/h(Afn)(T0-T∞)
=1/L√(hA)/√(kP)
=1/mL

η insulated tip =Q act/Q max possible

=√(hPkA)Ɵ0 tanh(mL)/h(Afin)(T0-T∞)
=tan h(mL)/mL

where Afin = convection heat transfer area of fin

= perimeter of fin (P) length of fin (L)
Fin Effectiveness

It is defined as the ration between heat transfer rate with fin and the heat transfer
rate without fin.

Εlong fin= √(hPkA)(T-T∞)/h(Af)(T0-T∞)[√Kp/√hA)]

ε insulated tip = Q fin/Q without fin = tanh mL√(hP/kA)

where, Ar area at the root equivalent to cross-sectional area of fin (Ac).

When
(i) ε = 1 : Fin does not affect the heat transfer at all.
(ii) ε = 1 : Fin act as insulation (if thermal conductivity (k) of fin material is low) .
(iii) ε = 1 : Heat transfer will be increased.
Heat transfer through fins

Note: 1. Fins are generally used where convection heat transfer coefficient (h)
values are relatively low i.e. when air or gas is the medium and heat transfer is by
natural convection.
43
2. Fin material should made of highly conductive materials. Aluminium is preferred:
low cost and weight, resistance to corrosion
3. Lateral surface area i.e. of the fin should be as high as possible.
4. Fins with parabolic and triangular profiles contain less material and are more
efficient requiring minimum weight.
5. The efficiency of most fins used in practice is above 90 percent.

44
 Chapter 7
MATHEMATICAL CALCULATIONS
7.1 FINS WITH CIRCULAR EXTENSION

Fig 7.1 Dimensions of Circular extensions

Area of Circle = 𝜃⁄360 × π r2 – ½ L (R-h)
R = L2 / (8h) + h/2
= 202 / (8×3) + 3/2
R = 18.16 ft
θ = 2 × sin-1 (L/2R)
= 2 × sin-1 (20/2×18.16)
θ = 67.4
Area of Circle A = 67.4/360 ×π (18.16)2 – ½ × 20 ×(18.16 – 3)
A = 40.84 square ft
Area of 12 Circle = 40.84 ×12
= 490.08 mm2
Area of Rectangle = 250 × 10 = 2500 mm2
Total Surface Area = Area of Rectangle + Area of 12 Circle
= 2500 + 490.08
= 2990.08 mm2

Perimeter of Circle = θ/360 × 2πr

= 67.4/360 ×2π×18.16
= 21.36 mm
Perimeter of Rectangle = 2 (length + breadth)
= 2 (150 + 10)
= 520 mm
Total Perimeter = Perimeter of rectangle + Perimeter of 12 Circle
= 520 + 21.3 ×12
= 776.36 mm
45
Q = √ℎ𝑃𝐾𝐴 tanh (mL) (t0 - tα)
H = 40 w/m2 ℃
P = 776.36 mm
A = 2990.08 mm2
ℎ𝑃
M=√
𝐾𝐴
T0 = 55℃
Tα = 30℃
L = 20 mm
K=40 W/mK
By substituting the known values
The heat transfer for fin with circular extension Q = 14.99 W
7.2 FINS WITH RECTANGULAR EXTENSIONS
Area of Large Rectangle = Length × Breadth
= 250 × 10 mm2
Area of smaller Rectangle = 20 × 4
= 80 mm2

Fig 7.2 Dimensions of Rectangular extensions

Area of 12 Rectangle = 80 × 12
= 960 mm2
Total Area = 960 + 2500
= 3460 mm2
Perimeter of large Rectangle = 2 ( length + breadth )
= 2 ( 250 + 10 )
= 260 × 2
= 520 mm
Perimeter of smaller rectangle = 2 (20+4)
= 48 mm
Total Perimeter = Perimeter of large rectangle + Perimeter of 12 smaller rectangle
- Length common for the larger & smaller rectangle

= 520 + 48 × 12 – 20 × 12
= 856 mm
46
Heat Transfer Q = √ℎ𝑃𝐾𝐴 tanh (mL) (t0 - tα)
H = 40 W/m2 0c
P = 856 mm
A = 3460 mm2
K =40 W/mK
M = √ℎ𝑃/𝐾𝐴
T0 = 550 C
Tα = 300 C
By substituting the known values the value of heat transfer for the rectangular fin with
extension is Q = 15.09 W
7.3 FINS WITH TRIANGLE EXTENSION

Fig 7.3 Dimensions of Triangular extensions

𝑜𝑝𝑝
Sin 17 =
10.44
Opp = 3.05 mm
Area of Triangle = ½ base × height
= ½ × 20 × 3.05
= 30.52 mm2
Area of 12 Triangles = 366.28 mm2
Total Area = Area of Rectangle + Area of Triangle
= 250 × 10 + 366.28
= 2866.28 mm2
Perimeter of Rectangle = 2 (250 + 10)
= 2 × 260
= 520 mm
Perimeter of Triangle = 10.44 + 10.44 + 20
= 40.88 mm
Total perimeter = Perimeter of Rectangle + Perimeter of Triangle
– Length of Bottom side of Triangle
= 520 + 40.88 ×12 – 20 × 12
= 770.56 mm
47
Q = √ℎ𝑃𝐾𝐴 tanh (mL) ( t0 – tα )
h = 40 W/ m2 0c
P = 770.56 mm
A = 2866.28 mm2
M = √ℎ𝑃/𝐾𝐴
T0 = 550C
Tα = 300 C
L = 20 mm
By substituting the known values
The heat transfer for fin with triangular extension is Q =14.8 W
7.4 FINS WITH TRAPEZOIDAL EXTENSION
Area of Trapezium = ½ (a+b) height
= ½ (20+10) × 3
= 45 mm2
Area of 12 Trapezium = 45×12
= 540 mm2
Area of Rectangle = 250×10
= 2500 mm2

Fig no 7.4 Dimensions of trapezoidal extensions

Total Surface Area = Area of rectangle + Area of 12 trapezium
= 2500 + 540
= 3040 mm2

PERIMETER
Perimeter of Rectangle = 2 (length+breadth)
= 2 (250+10)
= 260 × 2
= 520 mm
Perimeter of Trapezium without base length = 5.84+5.84+10
= 21.68 mm
48
Total Perimeter
= Perimeter of rectangle + Perimeter of 12 trapezium without base length
= 520 + 21.68 × 12
= 780.16 mm
Q = √ℎ𝑃𝐾𝐴 tanh (mL) ( t0 - tα )
h = 40 w/m2 0c
P = 780.16 mm
A = 3040 mm2
M = √ℎ𝑃/𝐾𝐴
T0 = 550C
Tα = 300 C
Lc = 20 mm
By substituting the known values the value of heat transfer trapezoidal extension is Q =
15.08 W.

7.9 HEAT TRANSFER OF FIN WITHOUT ANY EXTENSION

Q=√𝒉𝑷𝒌𝑨 tanh(mL) (T0-T∞)
Perimeter of the fin without extension=2(length+ breadth)
=2(250+10)
=520 mm =0.52 m
Area of the fin without extension = length * breadth
=250*10
=2500 mm2 = 0.0025 m2.
K=40 W/mK
h=40 W/mK
T0 = 550C
T∞ = 300C
By substituting the known values the value of heat transfer for the fin without extension is
Q = 10.11 W
Heat transfer calculated by using the heat transfer governing differential
equation for the fin of finite length and loses heat by convection for which the given length
of fin (l in m), thickness of fin (y in m), width of fin (b in m),thermal conductivity of fin (k
49
in W/m °C ), coefficient of convective heat transfer (h in W/m2 °C ) , temperature at base of
fin (to in °C),temperature of the ambient fluid (ta in °C). After the calculations of heat
transfer rate of various fin geometry now it is the time to compare the increase in heat transfer
rate for the given geometry of fin which is shown in Table-1. The fin without extensions is
having heat transfer Q = 10.11 W .
Table 7.1 Comparision of heat transfer for various extensions of fin
Extensions Heat transfer(in Increase in heat Percentage
W) transfer(in W) increase in heat
transfer( in %)
Rectangular 15.09 4.98 33
extension
Trapezium 15.06 4.95 32.86
extension
Triangular 14.8 4.69 31.68
extension
Circular 14.99 4.88 32.55
extension

50
 Chapter 8
CONCLUSION
The use of fin (extended surface) with extensions, provide efficient heat transfer:
• Fin with extensions provide near about 5 % to 13% more enhancement of heat transfer
as compare to fin without extensions.
• Heat transfer through fin with rectangular extensions higher than that of fin with other
types of extensions.
• Temperature at the end of fin with rectangular extensions is minimum as compare to
fin with other types of extensions.
• The effectiveness of fin with rectangular extensions is greater than other extensions.
• Choosing the minimum value of ambient fluid temperature provide the greater heat
transfer rate enhancement.

51
 REFERENCES
1. Maity, Dipak Heat Transfer and Flow Friction Characteristics of Plate Fin Heat Exchanger
Surfaces – A Numerical Study
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