UNIT-1 (Tutorial Sheet - 1)

1. The wall of an industrial furnace is constructed from 0.15 m thick fire-clay brick having
a thermal conductivity of 1.7 W/mK Measurements made during steady-state operation
reveal temperatures of 1400 K and 1150 K at the inner and outer surfaces, respectively.
What is the heat flux and rate of heat loss through a wall that is 0.5m × 1.2m on a side?

ANS: Heat Flux 2833 W/m2 , Heat Loss 1700 W.

2. A furnace wall is of three layers, first layer of insulation brick of 12 cm thickness of

conductivity 0.6 W/mK The face is exposed to gases at 870 C with a convection coefficient
of 110 W/m2 K . This layer is backed by a 10 cm layer of firebrick of conductivity 0.8 W/mK .
There is a contact resistance between the layers of 2.6×10−4 m2C/W . The third layer is
the plate backing of 10 mm thickness of conductivity 49 W/mK . The contact resistance
between the second and third layers is 1.5×10−4 m2C/W . The plate is exposed to air at
30 C with a convection coefficient of 15 W/m2 K . Determine the heat flow, the surface
temperatures and the overall heat transfer coefficient.

ANS: Heat Flux 2092.8 W/m2 , U = 2.491 W/m2C, Surface Temperatures 850. 97 C, 432.40
C, 431.86 C, 170.26 C, 169.95 C, 169.52 C.

3. A pipe carrying steam at 230 C has an internal diameter of 12 cm and the pipe thickness
is 7.5 mm. The conductivity of the pipe material is 49 W/mK the convective heat transfer
coefficient on the inside is 85 W/m2 K . The pipe is insulated by two layers of insulation
one of 5 cm thickness of conductivity 0.15 W/mK and over it another 5 cm thickness of
conductivity 0.48 W/mK . The outside is exposed to air at 35 C with a convection coeffi-
cient of 18 W/m2 K . Determine the heat loss for 5 m length. Also determine the interface
temperatures and the overall heat transfer coefficient based on inside and outside areas.

ANS: Heat Flow Rate 1234.06 W , U = 3.3574 W/m2 K — Based on inside area, U = 1.203
W/m2 K — Based on outside area, Surface Temperatures 222.3 C, 222.2 C, 77.04 C,

48.03 C.

4. A composite cylinder is made of 6 mm thick layers each of two materials of thermal

conductivity of 30 W/mK and 45 W/mK . The inside is exposed to a fluid at 500 C with a
convection coefficient of 40 W/m2 K and the outside is exposed to air at 35 C with a convec-
tion coefficient of 25 W/m2 K . There is a contact resistance of 1 × 10−3 m2 k/W between the
layers. Determine the heat loss for a length of 2 m and the surface temperatures. Inside
dia = 20 mm.

ANS: Heat Loss 1327 W, U = 22.7 W/m2 K — Based on inside area, U = 16.52 W/m2 K —
Based on outside area, Surface Temperatures 236 C, 234.35 C, 227.75 C, 227 C,
The temperature drops 264 C, 1.65 C, 6.60 C, 0.75 C.
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5. A spherical vessel of ID 0.3 m and thickness of 20 mm is made of steel with conductivity
of 40 W/mK . The vessel is insulated with two layers of 60 mm thickness of conductivity
0.05 W/mK and 0.15 W/mK . The inside surface is at −196 C. The outside is exposed to
air at 30 C with convection coefficient of 35 W/m2 K . There is a contact resistance of 1
× 10−3 m2 k/W between the two insulation. Determine the heat gain and also the surface
temperatures and the overall heat transfer coefficient based on the outside surface area of
the metallic vessel.

ANS: Heat Loss −76.6 W, U = 0. 932 W/m2 K — Based on outside area, Surface Temper-
atures −195.88 C, −8.75 C, −8.64 C, 27.93 C, The temperature drops 264 C, 1.65 C,
6.60 C, 0.75 C.

6. A cylinder of 12 cm diameter has a heat generation rate 106 W/m2 K . The conductivity of
the material is 200 W/mK . The surface is exposed to air at 30 C. The convection coefficient
is 500 W/m2 K . Determine the temperatures at the center and also at mid-radius. Also de-
termine the heat flow at the surface on unit area basis. Calculate the temperature gradients
at the mid radius and surface.

ANS: Temperature at radius r = 0 is 94.5 C, At mid radius r = 0.03 is 93.375 C, Heat flow
up to mid radius 2827.4 W/m, on area basis 1500 W/m2 , Heat flow at m the surface
11309.7 W/m, on area basis 30000 W/m2 .

7. A nuclear fuel rod is in the form of solid cylinder. The heat generation rate is 50 W/m3 and
the center temperature of the fuel rod is 360 C. The conductivity of the material is 24.2
W/mK . The heat generated is absorbed by a fluid at 200 C. Determine the convective heat
transfer required for diameter of (i) 25 mm and (ii) 16 mm.

ANS: 3941 W/m2 K , 1575 W/m2 K .

8. A wall 40 mm thick has its surfaces maintained at 0 C and 100 C. The heat generation
rate is 3.25×105 W/m3 . If the thermal conductivity of the material is 2 W/mK , determine
the temperature at the mid plane, the location and value of the mk maximum temperature
and the heat flow at either end.

ANS: 82.5 C, 0.01538 m, 101.74 C, 1500 W/m2 , 11500 W/m2 .

9. One end of long rod of diameter 10 mm is inserted into a furnace. The temperatures
measured at two points A and B, 39.3 mm apart gave 265 C and 147.5 C respectively.
If the convection coefficients is 35 W/m2 K , when exposed to air at 30 C, determine the
conductivity of the material.

ANS: 45 W ⁄ mk .
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10. Consider a large plane wall of thickness L = 0.04m. The wall surface at x = 0 is insulated,
while the surface at x = L is maintained at a temperature of 30◦C. The thermal conductiv-
ity of the wall is k = 30W/mK , and heat is generated in the wall at a rate of ġ = g0 e−0.5x/L
where g0 = 5 × 104 W/m3 . Assuming steady one-dimensional heat transfer, (a) express the
differential equation and the boundary conditions for heat conduction through the wall,
(b) obtain a relation for the variation of temperature in the wall by solving the differential
equation, (c) determine the temperature of the insulated surface of the wall, (d) and the
rate of heat flow.

11. A wall consists of three layers of 0.2 m concrete, 0.08 m of fiber glass insulation and
0.015 m of gypsum board (0.04 W/mK ). The convective heat transfer coefficients at inside
and outside surfaces are 15 W/m2 K and 45 W/m2 K respectively. The inside and outside
surface temperatures are 25 C and -10 C respectively. Calculate the overall heat transfer
coefficients for the wall and heat loss per unit area. (Use the data book to get the properties
of concrete and fiber glass).

12. Annular aluminum fins of rectangular profile are attached to a circular tube having an
outside diameter of 50 mm and an outer surface temperature of 200 C. The fins are 4 mm
thick and 15 mm long. The system is in ambient air at a temperature of 20 C, and the
surface convection coefficient is 40 W/m2 K . Find out the efficiency of fin, effectiveness of
fin and the rate of heat transfer per unit length of fin.

13. Determine the heat flow for (i) rectangular fins and (ii) triangular fin of 20 mm length
and 3 mm base thickness. Thermal conductivity = 45 W/mK. Convection coefficient =
100 W/m2 K, base temperature = 120°C surrounding fluid temperature = 35°C. Determine
also the fin effectiveness. Use the charts.

14. A circumferential fin on a pipe of 50 mm OD is 3 mm thick and 20 mm long. Ther-

mal conductivity = 45 W/mK. Convection coefficient = 100 W/m2 K, base temperature =
120°C surrounding fluid temperature = 35°C. Determine the (i) heat flow and effective-
ness (ii) If the pitch is 10 mm, determine the increase in heat flow for 1 m length of pipe.
Also determine the total efficiency.

15. A thin metal fins, 70 mm long and 3.5 mm thick, made of low carbon steel protrudes
into air at 35 C from a furnace wall at 200 C. There is insulation of plastic over the fin
surface and one end of the fin is insulated. The thickness of plastic about 0.12 mm. The
convective heat transfer coefficient is estimated at 22 W/m2 k.The conductivity of the metal
and plastic is 51.9 W/mk and 0.52 W/mk respectively. Determine the temperature at the tip
of the fin and efficiency of fin.