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Heat transfer: conduction, convection and radiation

Mechanical Engineering (B.E./B.Tech) · Heat transfer · free study notes for exams, placements and interviews

In short

Heat transfer is the study of the rate at which thermal energy crosses a boundary because of a temperature difference. Thermodynamics tells you how much energy moves between two states; heat transfer tells you how fast, and therefore how big the wall, fin, radiator, insulation or furnace must be. It happens by three modes - conduction through matter by molecular and electron interaction, convection by a moving fluid, and radiation by electromagnetic waves needing no medium. It is one of the heaviest-weighted sections in GATE Mechanical and in university Heat and Mass Transfer papers, and it is asked in design and plant interviews at BHEL, NTPC, L&T, Thermax, Tata Steel, ISRO, Godrej, Voltas, Blue Star, Cummins and every HVAC, boiler and automotive thermal-systems role.

Explained

Modes, Fourier's law and thermal conductivity

Steady conduction: resistance networks, generation, critical radius

Extended surfaces (fins) and transient conduction

Convection: boundary layers, dimensionless groups, correlations

Radiation: laws, properties and surface exchange

Indian standards, codes and practice

Key points

Formulas and examples

Fourier's law: Q = −kA (dT/dx) [W]; k in W/m·K, A in m², dT/dx in K/m
Plane wall: Q = kA(T₁−T₂)/L = ΔT/R, R = L/kA [K/W]
Cylinder: R = ln(r₂/r₁)/(2πkL); Sphere: R = (r₂−r₁)/(4πk r₁r₂); Film: R = 1/(hA)
Series network: Q = ΔT_overall / ΣR = U A ΔT, with 1/UA = ΣR
General conduction equation: ∂²T/∂x² + ∂²T/∂y² + ∂²T/∂z² + q̇/k = (1/α) ∂T/∂t ; α = k/ρc
Internal generation: slab (2L, both faces at T_w) ΔT_max = q̇L²/2k; cylinder q̇R²/4k; sphere q̇R²/6k
Critical radius: r_cr = k/h (cylinder), 2k/h (sphere)
Fin: m = √(hP/kA_c); Q = √(hPkA_c)·θ_b·tanh(mL); η = tanh(mL)/(mL); ε = Q_fin/(hA_cθ_b)
Lumped capacitance: (T−T∞)/(Tᵢ−T∞) = exp(−hA_s t/ρVc) = exp(−Bi·Fo); τ = ρVc/hA_s [s]
Bi = hL_c/k, L_c = V/A_s; Fo = αt/L_c²; semi-infinite solid: (T−Tᵢ)/(T_s−Tᵢ) = erfc[x/(2√(αt))]
Newton's law of cooling: Q = hA(T_s − T∞); h in W/m²K
Re = ρVD/µ; Pr = µc_p/k; Nu = hL/k; Gr = gβΔTL³/ν²; Ra = Gr·Pr; St = h/(ρVc_p)
Laminar flat plate: δ = 5x/√Re_x; Nu_x = 0.332 Re_x0.5 Pr1/3; Nu_avg = 0.664 Re_L0.5 Pr1/3
Turbulent flat plate: Nu_avg = 0.037 Re_L0.8 Pr1/3
Fully developed laminar tube: Nu = 3.66 (constant T_s), 4.36 (constant q); Dittus-Boelter: Nu = 0.023 Re0.8 Prn
Sieder-Tate (large µ variation): Nu = 0.027 Re0.8 Pr1/3 (µ_b/µ_w)0.14
Free convection, vertical plate: Nu = 0.59 Ra1/4 for 10⁴<Ra<10⁹; Nu = 0.10 Ra1/3 for 10⁹<Ra<10¹³
Colburn analogy: St·Pr2/3 = C_f/2
Stefan-Boltzmann: E_b = σT⁴, σ = 5.67×10⁻⁸ W/m²K⁴, T in K; grey surface E = εσT⁴
Wien: λ_max·T = 2898 µm·K; α + ρ + τ = 1; Kirchhoff α = ε
Large parallel grey plates: q = σ(T₁⁴−T₂⁴)/(1/ε₁ + 1/ε₂ − 1) [W/m²]
Two-surface enclosure: Q₁₂ = σ(T₁⁴−T₂⁴)/[(1−ε₁)/ε₁A₁ + 1/A₁F₁₂ + (1−ε₂)/ε₂A₂]
Small grey body in large enclosure: Q = ε₁A₁σ(T₁⁴−T_sur⁴)
Radiation coefficient: h_r = εσ(T_s²+T_sur²)(T_s+T_sur); h_total = h_c + h_r
Materialk (W/m·K), approx.Materialk (W/m·K), approx.
Silver / copper420 / 385-400Window glass0.8
Aluminium205-237Water (liquid, 20 °C)0.60
Mild steel45-54Mineral wool0.04
Stainless steel 30415-16PU foam / EPS0.022-0.035
Fireclay brick / concrete0.7-1.1 / 1.4Air (still, 27 °C)0.026

Example 1 - Composite furnace wall (series resistances, per m²). Flue gas at 900 °C, h_i = 30; firebrick 200 mm (k = 1.2); insulating block 100 mm (k = 0.08); steel casing 10 mm (k = 45); ambient air 30 °C, h_o = 10.

Example 2 - Critical radius on an electric cable. Bare conductor radius 5 mm, surface held at 70 °C, ambient 25 °C, insulation k = 0.2, h = 10 (per metre length).

Example 3 - Aluminium fin. k = 200, fin 100 mm wide × 50 mm long × 1 mm thick, base 100 °C, air 25 °C, h = 25, insulated tip.

Example 4 - Forced convection of water in a tube. Water, bulk mean 40 °C, V = 1 m/s, D = 25 mm; ρ = 992, µ = 653×10⁻⁶, k = 0.631, Pr = 4.32. Wall at 80 °C (water being heated).

Example 5 - Radiation between plates, and a shield. Large parallel plates, T₁ = 800 K, ε₁ = 0.8; T₂ = 500 K, ε₂ = 0.6.

ModeDriving potentialRate lawNeeds medium?Typical coefficient
ConductiondT/dxQ = −kA dT/dxYes (solid or still fluid)k = 0.02-400 W/m·K
ConvectionT_s − T∞Q = hAΔTYes (moving fluid)h = 5-50,000 W/m²K
RadiationT_s⁴ − T_sur⁴Q = εσA(T_s⁴−T_sur⁴)Noh_r rises steeply with T

Where it is used

Interview questions

Common mistakes

Related topics

Heat exchangers: LMTD and effectiveness-NTU · Thermodynamics: laws and properties · Fluid mechanics: boundary layers and pipe flow · Refrigeration and air conditioning · Power plant engineering (boilers and condensers) · Mass transfer and diffusion.

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