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Introduction…
The objective of this chapter is to introduce you to thermal systems engineering chapter objective
using several contemporary applications. Our discussions use certain terms that
we assume are familiar from your background in physics and chemistry. The
roles of thermodynamics, fluid mechanics, and heat transfer in thermal systems
engineering and their relationship to one another also are described. The
presentation concludes with tips on the effective use of the book.
30°
25 in.2 inlet area
Thorax
Lung Steam generator
Electric
Combustion Stack power
gas cleanup
Turbine
Coal Air Steam Cooling
Heart Generator tower
Condenser
Ash
Human cardiovascular system
Condensate
Cooling water
Electrical power plant
system is a complex combination of fluid flow and heat transfer components that regulates
the flow of blood and air to within the relatively narrow range of conditions required to
maintain life.
In the next section, three case studies are discussed that bring out important features of
thermal systems engineering. The case studies also suggest the breadth of this field.
Shower head
Shower head
Hot
Diverter valve
To shower
head
Cold Cold water
faucet Cold
water
Figure 1.2 Home hot water supply. (a) Overview. (b) Faucet and shower head.
the number of valves, elbows, and other fittings required. As shown in Fig. 1.2b, the faucet
and the shower head must be designed to provide the desired flow rate while mixing hot and
cold water appropriately.
From this example we see some important ideas relating to the analysis and design of
thermal systems. The everyday system that delivers hot water for your shower is composed
of various components. Yet their individual features and the way they work together as a
whole involve a broad spectrum of thermodynamics, fluid mechanics, and heat transfer prin-
ciples.
Generator
Inverter
Batteries
Electric motor
Gasoline engine
(b) Regenerative braking mode with energy flow from wheels to battery
Figure 1.3 Hybrid electric vehicle combining gasoline-fueled engine, storage batteries, and
electric motor. (Illustrations by George Retseck.)
The energy source for such hybrid vehicles is gasoline burned in the engine. Because of
the ability to store energy in the batteries and use that energy to run the electric motor, the
gasoline engine does not have to operate continuously. Some HEVs use only the electric
motor to accelerate from rest up to about 15 miles per hour, and then switch to the gasoline
engine. A specially designed transmission provides the optimal power split between the gaso-
line engine and the electric motor to keep the fuel use to a minimum and still provide the
needed power.
Most HEVs use regenerative braking, as shown in Fig. 1.3b. In conventional cars, step-
ping on the brakes to slow down or stop dissipates the kinetic energy of motion through
the frictional action of the brake. Starting again requires fuel to re-establish the kinetic
energy of the vehicle. The hybrid car allows some of the kinetic energy to be converted
during braking to electricity that is stored in the batteries. This is accomplished by the
electric motor serving as a generator during the braking process. The net result is a
significant improvement in fuel economy and the ability to use a smaller-sized gasoline
engine than would be possible to achieve comparable performance in a conventional
vehicle.
The overall energy notions considered thus far are important aspects of thermodynam-
ics, which deals with energy conversion, energy accounting, and the limitations on how en-
ergy is converted from one form to another. In addition, there are numerous examples of
fluid mechanics and heat transfer applications in a hybrid vehicle. Within the engine, air,
6 Chapter 1. What Is Thermal Systems Engineering?
fuel, engine coolant, and oil are circulated through passageways, hoses, ducts, and mani-
folds. These must be designed to ensure that adequate flow is obtained. The fuel pump and
water pump also must be designed to achieve the desired fluid flows. Heat transfer princi-
ples guide the design of the cooling system, the braking system, the lubrication system, and
numerous other aspects of the vehicle. Coolant circulating through passageways in the engine
block must absorb energy transferred from hot combustion gases to the cylinder surfaces so
those surfaces do not become too hot. Engine oil and other viscous fluids in the transmis-
sion and braking systems also can reach high temperatures and thus must be carefully
managed.
Hybrid electric vehicles provide examples of complex thermal systems. As in the case of
hot water systems, the principles of thermodynamics, fluid mechanics, and heat transfer ap-
ply to the analysis and design of individual parts, components, and to the entire vehicle.
Pin lead
Metal film
Pre-form solder paste
(b)
(c)
(a) (d)
Figure 1.4 Soldering printed-circuit boards (a) with pre-form solder paste applied to integrated
circuit pins and terminal pads (b) enter the solder-reflow oven (c) on a conveyor and are heated to
the solder melting temperature by impinging hot air jets (d ).
1.3 Analysis of Thermal Systems 7
PCB and its components must be gradually and uniformly heated to avoid inducing thermal
stresses and localized overheating. The PCB is then cooled to near-room temperature for
subsequent safe handling.
The PCB prepared for soldering is placed on a conveyor belt and enters the first zone
within the solder reflow oven, Fig. 1.4c. In passing through this zone, the temperature of the
PCB is increased by exposure to hot air jets heated by electrical resistance elements, Fig. 1.4d.
In the final zone of the oven, the PCB passes through a cooling section where its tempera-
ture is reduced by exposure to air that has been cooled by passing through a water-cooled
heat exchanger.
From the foregoing discussion, we recognize that there are many aspects of this manu-
facturing process that involve electric power, flow of fluids, air-handling equipment, heat
transfer, and thermal aspects of material behavior. In thermal systems engineering, we per-
form analyses on systems such as the solder-reflow oven to evaluate system performance or
to design or upgrade the system. For example, suppose you were the operations manager of
a factory concerned with providing electrical power and chilled water for an oven that a ven-
dor claims will meet your requirements. What information would you ask of the vendor? Or,
suppose you were the oven designer seeking to maximize the production of PCBs. You might
be interested in determining what air flow patterns and heating element arrangements would
allow the fastest flow of product through the oven while maintaining necessary uniformity
of heating. How would you approach obtaining such information? Through your study of
thermodynamics, fluid mechanics, and heat transfer you will learn how to deal with ques-
tions such as these.
In your earlier studies in physics and chemistry, you were introduced to these laws. In
this book, we place the laws in forms especially well suited for use in thermal systems
engineering and help you learn how to apply them.
Thermodynamics
Conservation of mass
Conservation of energy
Second law of thermodynamics
Properties
o
m
er
Th
Heat Transfer
Thermal Systems Engineering
Conduction
H ea
Analysis directed to
Convection
t transfer
Design
Radiation
Operations/Maintenance
Multiple Modes
Marketing/Sales
Costing
•
•
•
Fl
uid
s
Fluid Mechanics
Fluid statics
Conservation of momentum
Mechanical energy equation
Similitude and modeling
Figure 1.5 The disciplines of thermodynamics, fluid mechanics, and heat transfer involve
fundamentals and principles essential for the practice of thermal systems engineering.
1.4 How to Use This Book Effectively 9
effects and lift/drag forces. The concept of similitude is used extensively in scaling measure-
ments on laboratory-sized models to full-scale systems.
Heat transfer is concerned with energy transfer as a consequence of a temperature dif-
ference. As shown in Fig. 1.5, there are three modes of heat transfer. Conduction refers
to heat transfer through a medium across which a temperature difference exists. Convection
refers to heat transfer between a surface and a moving or still fluid having a different
temperature. The third mode of heat transfer is termed thermal radiation and represents
the net exchange of energy between surfaces at different temperatures by electromagnetic
waves independent of any intervening medium. For these modes, the heat transfer rates
depend on the transport properties of substances, geometrical parameters, and tempera-
tures. Many applications involve more than one of these modes; this is called multimode
heat transfer.
Returning again to Fig. 1.5, in the thermal systems engineering box we have identified
some application areas involving analysis. Earlier we mentioned that design requires analy-
sis. Engineers also perform analysis for many other reasons, as for example in the operation
of systems and determining when systems require maintenance. Because of the complexity
of many thermal systems, engineers who provide marketing and sales services need analy-
sis skills to determine whether their product will meet a customer’s specifications. As engi-
neers, we are always challenged to optimize the use of financial resources, which frequently
requires costing analyses to justify our recommendations.
Problems
1.1 List thermal systems that you might encounter in everyday 1.6 Contact your local utility for the amount you pay for elec-
activities such as cooking, heating or cooling a house, and tricity, in cents per kilowatt-hour. What are the major contrib-
operating an automobile. utors to this cost?
1.2 Using the Internet, obtain information about the operation of 1.7 A newspaper article lists solar, wind, hydroelectric, geo-
a thermal system of your choice or one of those listed or shown thermal, and biomass as important renewable energy resources.
in Fig. 1.1. Obtain sufficient information to provide a descrip- What is meant by renewable? List some energy resources that
tion to your class on the function of the system and relevant ther- are not considered renewable.
modynamics, fluid mechanics, and heat transfer aspects. 1.8 Reconsider the energy resources of Problem 1.7. Give
1.3 Referring to the thermal systems of Fig. 1.1, in cases assigned specific examples of how each is used to meet human needs.
by your instructor or selected by you, explain how energy is 1.9 Our energy needs are met today primarily by use of fossil
converted from one form to another and how energy is stored. fuels. What fossil fuels are most commonly used for (a) trans-
1.4 Consider a rocket leaving its launch pad. Briefly discuss the portation, (b) home heating, and (c) electricity generation?
conversion of energy stored in the rocket’s fuel tanks into other 1.10 List some of the roles that coal, natural gas, and petroleum
forms as the rocket lifts off. play in our lives. In a memorandum, discuss environmental,
political, and social concerns regarding the continued use of
these fossil fuels. Repeat for nuclear energy.
1.11 A utility advertises that it is less expensive to heat water
for domestic use with natural gas than with electricity. Deter-
mine if this claim is correct in your locale. What issues deter-
mine the relative costs?
1.12 A news report speaks of greenhouse gases. What is meant
by greenhouse in this context? What are some of the most preva-
lent greenhouse gases and why have many observers expressed
concern about those gases being emitted into the atmosphere?
1.13 Consider the following household appliances: desktop
computer, toaster, and hair dryer. For each, what is its func-
tion and what is the typical power requirement, in Watts? Can
it be considered a thermal system? Explain.
Figure P1.4
1.14 A person adjusts the faucet of a shower as shown in Fig- 1.21 Automobile designers have worked to reduce the aerody-
ure P1.14 to a desired water temperature. Part way through the namic drag and rolling resistance of cars, thereby increasing
shower the dishwasher in the kitchen is turned on and the tem- the fuel economy, especially at highway speeds. Compare the
perature of the shower becomes too cold. Why? sketch of the 1920s car shown in Figure P1.21 with the ap-
pearance of present-day automobiles. Discuss any differences
that have contributed to the increased fuel economy of mod-
ern cars.
Hot
Shower
Dishwasher
Figure P1.21
Cold 1.22 Considering the hot water supply, hybrid electric vehi-
Water cle, and solder-reflow applications of Sec. 1.2; give exam-
meter
Cold
Hot water ples of conduction, convection, and radiation modes of heat
heater transfer.
1.23 A central furnace or air conditioner in a building uses a
fan to distribute air through a duct system to each room as
Figure P1.14 shown in Fig. P1.23. List some reasons why the temperatures
might vary significantly from room to room, even though each
1.15 The everyday operation of your car involves the use of room is provided with conditioned air.
various gases or liquids. Make a list of such fluids and indi-
cate how they are used in your car.
1.16 Your car contains various fans or pumps, including the
radiator fan, the heater fan, the water pump, the power steering
pump, and the windshield washer pump. Obtain approximate Conditioned air Cooling
supply duct Heating and fan
values for the power (horsepower or kilowatts) required to
operate each of these fans or pumps. Outdoor air
intake
1.17 When a hybrid electric vehicle such as the one described
in Section 1.2.2 is braked to rest, only a fraction of the vehi-
cle’s kinetic energy is stored chemically in the batteries. Why
only a fraction?
1.18 Discuss how a person’s driving habits would affect the fuel
economy of an automobile in stop-and-go traffic and on a Air return
freeway.
1.19 The solder-reflow oven considered in Section 1.2.3 oper-
ates with the conveyer speed and hot air supply parameters ad-
justed so that the PCB soldering process is performed slightly
above the solder melting temperature as required for quality
joints. The PCB also is cooled to a safe temperature by the Figure P1.23
time it reaches the oven exit. The operations manager wants to
increase the rate per unit time that PCBs pass through the oven.
How might this be accomplished? 1.24 Figure P1.24 shows a wind turbine-electric generator
1.20 In the discussion of the soldering process in Section mounted atop a tower. Wind blows steadily across the turbine
1.2.3, we introduced the requirement that the PCB and its blades, and electricity is generated. The electrical output of the
components be gradually and uniformly heated to avoid ther- generator is fed to a storage battery. For the overall thermal
mal stresses and localized overheating. Give examples from system consisting of the wind-turbine generator and storage
your personal experience where detrimental effects have been battery, list the sequence of processes that convert the energy
caused to objects heated too rapidly, or very nonuniformly. of the wind to energy stored in the battery.
Problems 13
Still, ambient
air