CHAPTER 4

CALCULATION OF HEAT TRANSFER IN RADIATOR

Radiator dimensions are obtained as follow by measuring the old radiator of

62 kW diesel engine. They are listed in Table 4.1.
Table 4.1. 62 kW Diesel Engine Radiator Dimensions

Name Symbol Value Unit

Core length Lc 0.52 m

Core height Hc 0.39 m

Core width Wc 0.042 m

Tube length Lt 0.39 m

Tube height Ht 0.0022 m

Tube width Wt 0.0112 m

Fin length Lf 0.0046 m

Fin width Wf 0.042 m

Fin thickness Hf 0.0002 m

Number of tubes Nt 135 -

Number of fins per tube, left and right Nf 372 -

4.1. Calculation the Amount of Heat Removed from Radiator

Density of fuel is calculated from
Using Equation 3.1
ρf
SGf =
ρw
SGf = 0.85
ρw = 1000 kg/m3

ρf
0 . 85=
1000
 40

ρf =0 .85×1000

= 850 kg/m3
To find the mass of fuel supplied per hour of engine at maximum operating
condition, it can be calculated from
Using Equation 3.2
ṁf = Fuel consumption in liter ¿ ρf
−3 3
11L 10 m 160km
= × ×ρ f ×
100km 1L 1hr
−3
11×10 ×850×160
=
100
= 14.96 kg/hr
Total amount of heat introduced into the engine can be calculated from
Using Equation 3.3
Qtotal =ṁ f ×L .C .V

L.C.V = 42.6 MJ/kg

14 .96
Qtotal =42 . 6×10 6×
3600
= 177026.67 W

= 177.027 kW
Heat carried away by cooling water is about 35% of total amount heat
introduced in to the engine
Using Equation 3.4
Qcool =35%×Qtotal

=0 . 35×177 . 027

= 61.96 kW

In order to calculate the heat to be dissipated in the radiator making allowance

for the dirtying process in the radiator surface, the design amount of heat is increased
by 10 percent.
Using Equation 3.5
 41

Qrad=1. 1×Qcool
=1 .1×61. 96
= 68.16 kW
Table 4.2. Result of Amount of Heat Transfer in Radiator

Name Symbol Value Unit

Total amount of heat introduced into the engine Qtotal 177.027 kW

Amount of heat rejected to the cooling Qcool 61.96 kW

Amount of heat removed from radiator Qrad 68.16 kW

4.2. Calculation of Heat Transfer Coefficient in Radiator

Two type of convective heat transfer coefficient are used to calculate the heat
transfer rate in radiator. The first one is convective heat transfer coefficient at water
for internal flow of radiator. The second is convective heat transfer coefficient at air
for external flow of radiator.

4.2.1. Calculation of Convective Heat Transfer Coefficient for Internal Flow (Water)
The average temperature of water must be calculated to find the fluid
properties:
Let, radiator inlet water temperature =100°C (maximum coolant
temperature between 100-120°C)
Assume, temperature drop of water at radiator exit, (6- 12° C ) =10° C
Using Equation 3.6
ΔT w
T w,avg =T w,in−
2
10
=100−
2

= 95°C

Table 4.3. Properties of Water at Average Temperature 95°C

Name Symbol Value Unit

ρw 3
Density 961.9 kg/m
 42

Specific heat Cp 4.21 kJ/kgK

w

Thermal conductivity kw 0.675 W/mK

Dynamic viscosity μw 0.0002964 kg/ms
Prandtl number Pr 1.886 -
The required amount of water flow rate is calculated from
Using Equation 3.7
Qrad
V w=
ρw C P ΔTw
w

68 . 16
=
961 . 9×4 . 21×10
= 1.683×10-3 m3/s

= 6058.8 L/hr
Cross-sectional area of tube is
Using Equation 3.14
A t =W t ×H t
=0 . 0112×0 .0022
−5 2
=2 . 464×10 m
The velocity of water flow in tube is
Using Equation 3.8
Vw
v w=
At ×N t
−3
1 .683×10
=
2. 464×10−5 ×135

= 0.506 m/s
Wetted parameter of tube is
Using Equation 3.15
Pt =2W t +2H t
= 2×0 . 0112+2×0 .0022

= 0.0268 m
 43

The hydraulic diameter defined as

Using Equation 3.13
At
D h =4×
Pt
−5
2. 464×10
4×
= 0.0268
−3
=3 . 678×10 m
For flow in tube Reynolds number is defined as
Using Equation 3.10
ρ w v w Dh
Re=
μw
−3
961 .9×0.506×3.678×10
=
0.0002964
=6039 . 68
For fully developed turbulent flow in smooth tube, friction factor and Nusselt
number correlation include the range (0.5≤ Pr ≤ 2000, 2300< Re <10000) where most
automotive radiators operate.
Using Equation 3.11

f =(1 .58lnRe−3 . 28)−2

=(1.58×ln(6039.68 )−3.28)−2

=9 . 11×10−3
Using Equation 3.12
f/2( Re−1000 )×Pr
Nu = 1 2
2 3
1+12 .7 ( f/2) ×( Pr −1 )

9 .11×10−3 /2×(6039 . 68−1000 )×1 . 886

= 1 2
1+12. 7×(9 .11×10−3 /2 )2 ×(1 .886 3 −1)
Nu=29. 83

Once the Nusselt number is available, the convection heat transfer coefficient
is determined from
Using Equation 3.9
 44

Nu×k w
hw =
Dh
29 . 83×0. 675
=
3 .678×10−3
= 5474.51 W/m2K

4.2.2. Calculation of Convective Heat Transfer Coefficient for External Flow (Air)
The average temperature of air must be calculated to find the correct material
properties;
Let, radiator inlet air temperature = 25°C (ambient temperature)
Assume, temperature rise of air at radiator exit =35° C
Using Equation 3.16
ΔT a
T a,avg=T a,in +
2
35
=25+
2
= 42.5°C
Table 4.4. Properties of Air at Average Temperature 42.5° C

Name Symbol Value Unit

ρa 3
Density 1.119 kg/m
Specific heat CP 1.007 kJ/kgK
a

Thermal conductivity ka 0.02754 W/mK

Kinematic viscosity υa 17.16×10−6 2
m /s
Prandtl number Pr 0.7056 -

The required amount of air flow rate is calculated from

Using Equation 3.17
Q rad
V a=
ρa C P ΔT a
a

68 . 16
=
1. 119×1. 007×35
= 1.728 m3/s
Area of core is
 45

Using Equation 3.19

A c =H c ×Lc
=0.39×0.52
= 0.2028 m2
The velocity of air flow through the radiator core is
Using Equation 3.18
Va
v a=
Ac −( N t ×H t ×Lt )
1 .728
=
0 .2028−(135×0 . 0022×0 .39 )
va = 19.869 m/s

= 44.45 mph
Reynolds number is defined as
Using Equation 3.23
v a ×W f
Re=
υa
19 . 869×0 . 042
=
17 . 16×10−6
=48630. 42
Colburn factor can be defined as a function of Reynolds number as follows.
For best accuracy select data for a coolant flow rate where ℜ< 4000 and (0.5≤ Pr ≤ 10)
Using Equation 3.22
−0 .277
j=0.5457Re
−0.277
=0 .5457×48630 . 42
=0 . 02746
The Colburn factor is a modified Stanton number to take into account the
moderate variations in the fluid Prandtl number. It is defined as
Using Equation 3.21
2
3
j=St×Pr
j
St= 2
3
Pr
 46

0 . 02746
= 2
3
0 . 7056
=0 . 03465

The Stanton number is another dimensionless representation of the heat

transfer coefficient. It is defined as
Using Equation 3.20
ha
St=
ρa v a C p
a

ha =St×ρa ×v a×C P
a

3
ha =0 . 03465×1 . 119×19 . 869×1 . 007×10

= 775.78 W/m2

4.2.3. Calculation of Fin Efficiency

The extended surface efficiency of air-side surface is related to the fin
efficiency of the extended surface as follow;
Using Equation 3.26

2h a

Where,
m=
√ k copper ×H f

k copper = 398 W/mK ( Thermal conductivity of copper at average air

temperature)

2×783 .62
m=
√ 398×0. 0002
= 140.32 m-1
Using Equation 3.27
Hf
l c=L f +
2
0. 0002
=0 . 0046+
2
−3
=4 .7×10 m
Using Equation 3.25
 47

tanh(mlc )
ηfin =
ml c
−3
tanh(140 .32×4 . 7×10 )
=
140 . 32×4 .7×10−3
= 0.8765

= 87.65 %
Using Equation 3.28
A f =2×W f ×lc
−3
=2×0 .042×4 . 7×10
=3 . 948×10−4 m2
Using Equation 3.29
A b =3Lt W t −H f W f N f

Ab =3×0 .39×0 . 0112−0. 0002×0. 042×372

=9 . 98×10−3 m2

Using Equation 3.30

A fin,base =N f A f + A b
−4 −3
=372×3. 948×10 +9 . 98×10
= 0.157 m2
Using Equation 3.24
N f × Af
ηo =1− ( 1−η fin )
A fin,base

372×3. 948×10−4
=1− ×(1−0.8765 )
0.157
= 0.8845

= 88.45 %
A typical automobile radiator has a fin efficiency of over 95% at 80 to 90
km/hr automobile speed. Calculated result of fin efficiency is nearly 88.45%.

4.2.4. Calculation of Heat Transfer Rate in Radiator

Using Equation 3.33
 48

C w = ṁw ×C P
w

=V w ×ρw ×C p
w

−3 3
=1 .683×10 ×961 . 9×4 . 21×10
= 8615.48 W/K
Using Equation 3.34
C a= ṁ a×C P
a

=V a× ρa ×C p
a

3
=1 .728×1. 119×1. 007×10
= 1947.17 W/K
Cmin = Ca = 1947.17 W/K
Cmax = Cw = 8615.48 W/K
Total external surface area of radiator core
Using Equation 3.38
A ex = Afin,base ×N t
Aex =0 . 157×135

= 21.2 m2
Total internal surface area of radiator core
Using Equation 3.39
A in =( 2W t +2H t ) Lt N t

=(2×0 . 0112+2×0. 0022)×0 .39×135

= 1.411 m2
Using Equation 3.37
1
UA=
1 1
+
ηo h a Aex h w A in
1
=
1 1
+
0. 8845×775. 78×21. 2 5474 . 51×1 . 411
= 5045.4 W/K
The number of transfer units is expressed as
Using Equation 3.36
 49

UA
NTU=
C min
5045.4
=
1947.17
=2.59
Heat capacity rate ratio is
Using Equation 3.40
C min
Cr=
Cmax
1947.17
=
6815.48
= 0.2857
The radiator utilizes a cross-flow single pass design where both fluids remain
unmixed. The effectiveness relation for this type of heat exchanger can be determined
from
Using Equation 3.35
0 . 22
NTU 0 .78

{ [ e(− CrNTU )
−1 ]}
Cr
ε =1−e
0 . 22
2 .59 0 .78

{ [ e(−0. 2857 ×2. 59 )

−1 ]}
0 .2857
ε =1−e
= 0.8574

= 85.74 %
For a given flow arrangement can be expressed in terms of two dimensionless
parameters, the heat capacity rate ratio Cmin/ Cmax and the ratio of the overall
conductance to the smaller heat capacity rate, UA/C min, the effectiveness is about 86%
(from Fig. B.6).
Maximum heat transfer rate is
Using Equation 3.32

Qmax =C min (T w,in −T a,in )

The actual heat transfer rate of radiator is calculated from
Using Equation 3.31
Qrad=εQ max
 50

=ε C min (T w,in−T a,in )

=0 . 8574×1947 .17×(100−25 )
= 125212.8 W
= 125.21 kW

4.3. Calculation of Radiator Outlet Temperature for Water and Air

Calculated the temperature outlet of water is
Using Equation 3.41
Q rad
T w,out =T w,in −
Cw

125212. 8
=100−
6815 . 48
=81 . 63° C
Temperature different between inlet and outlet water in radiator is
Using Equation 3.42
ΔT w =T w,in −T w,out
=100−81. 63
=18 . 37 °C
Calculated the temperature outlet of air is
Using Equation 3.43
Qrad
T a,out=T a,in +
Ca
125212 . 8
=25+
1947 . 17
=89 . 31° C

Temperature rise between inlet and outlet air in radiator is

Using Equation 3.44
ΔT a =T a,out −T a,in
=89 . 31−25
=64 . 31 °C
Heat lost by water
Using Equation 3.45
 51

Q w =ṁw C P w (T w,in −T w,out )

3
=1 .619×4 .21×10 ×(100−81. 63)
= 125209.74 W

= 125.21 kW
Heat gain by air
Using Equation 3.46
Qa =ṁa C P a (T a,out −T a,in )

=1. 934×1. 007×103 ×(89.31−25)

= 125246.17 W

= 125.25 kW
By the first law of thermodynamics, the rate of heat transfer from the hot fluid

Qw is equal to the rate of heat transfer to the cold fluid Qa .

Using Equation 3.47
Qw ≅ Qa
Design condition of heat transfer rate is 68.16 kW and calculated result of heat
transfer rate is 125.21 kW. Therefore, in order to get design condition heat transfer
rate, it need to iterate by changing the temperature outlet of water and air. The results
are as follow in Table 4.5.
Table 4.5. Comparison of Data Results by Changing the Radiator Outlet Temperature
of Water and Air

First Calculation
Description Symbol Iteration Data Unit
Data
Convective heat transfer
hw 5474.51 2785.78 W/m2K
coefficient of water
Convective heat transfer
ha 775.78 514.3 W/m2K
coefficient of air
Overall heat transfer
UA 5045.4 2824 W/K
coefficient

Number of transfer units NTU 2.59 2.665 -

Heat exchanger ε 85.74 86.35 %

effectiveness
 52

Temperature outlet of
T w,out 81.63 81.5 °C
water

Temperature outlet of air T a,out 89.31 89.76 °C

Temperature drop of water ΔT w 18.37 18.5 °C

Temperature rise of air ΔT a 64.31 64.76 °C

Heat transfer rate of
Qrad 125.21 68.64 kW
radiator

Table 4.6. Comparison of Heat Transfer Rate

Description Design Data First Calculation Data Iteration Data

Heat transfer rate 68.16 kW 125.21 kW 68.64 kW

4.4. Results of Heat Transfer in Radiator of 62 kW Diesel Engine

The results of heat transfer of 62 kW diesel engine radiator at specified mass
flow rates and temperatures inlet and outlet of water and air are shown in Table 4.7.
Table 4.7. Results of Heat Transfer in Radiator of 62 kW Diesel Engine

No. Description Symbol Value Unit

Total amount of heat introduced into Qtotal
1 177.027 kW
the engine

2 Heat rejected to the cooling system Qcool 61.96 kW

3 Amount of heat removed from radiator Qrad 68.16 kW

Convective heat transfer coefficient of hw 2

4 2785.78 W/m K
water

Convective heat transfer coefficient of ha 2

5 514.3 W/m K
air
6 Overall heat transfer coefficient UA 2824 W/K
7 Number of transfer unit NTU 2.665 -
8 Heat exchanger effectiveness ε 86.35 %

9 Heat transfer rate of radiator Qrad 68.64 kW

10 Temperature outlet of water T w,out 81.5 °C

11 Temperature outlet of air T a,out 89.76 °C

 53

12 Temperature drop of water ΔT w 18.5 °C

13 Temperature rise of air ΔT a 64.76 °C