Lecture 7: Convective Heat Transfer: Reynolds Analogy
Lecture 7: Convective Heat Transfer: Reynolds Analogy
Lecture 7: Convective Heat Transfer: Reynolds Analogy
General
(a) Reducing the performance. This tends to be a 1-3% effect on Isp only, and is
therefore secondary.
(b) Creating great difficulties in the design of hot-side structures that have to
survive heat fluxes in the 107 − 108 w / m2 range.
The principal modes of heat transfer to nozzle and combustor walls are
convection and radiation. Of these, convection dominates, and radiation tends to be
important only for particle-laden flows from solid propellant rockets.
We will review here the compressible 2D boundary layer equations in order to extract
information on wall heat transfer.
∂ ( ρu ) ∂ ( ρv)
Continuity + =0 (1)
∂x ∂y
∂u ∂u ∂p ∂τxy ∂ ⎛ ∂u ⎞
X-Momentum ρu + ρv + = = ⎜µ ⎟ (2)
∂x ∂y ∂x ∂y ∂y ⎝ ∂y ⎠
∂P
Y-Momentum =0 (3)
∂y
u2
where ht = h + is the specific total enthalpy, and µ is the viscosity. For a
2
laminar flow, µ = µ ( T ) is a fluid property. Rocket boundary layers are almost always
turbulent, and µ is then the “turbulent viscosity”, where momentum transport is
effected by the random motion of turbulent “eddies”. If these eddies have a velocity
scale u' and a length scale l ' , we have, in order-of-magnitude.
where u' is some fraction of the local u, and l ' tends to be of the order of the wall
distance y. The important points about (5) are
Similarly, the last term on the right in the energy balance, representing the
convergence of heat flux, contains the “turbulent thermal conductivity” K ∼ ρ cpu'l' .
Once again, we notice that K is here proportional to density. We also note that the
“turbulent Prandtl number”
µ t cp
Pr = ∼ 1 (from the orders of magnitude)
kt
It is of some interest to note the origin and composition of the viscous term in
equation (4). If we collect the dot products u i τ t around a fluid element as shown (in
B.L. approximation),
2
∂ ∂τxy ∂u ∂ ⎛ ∂u ⎞ ⎛ ∂u ⎞
∂y
(
uτxy = u )
∂y
+ τxy
∂y
=u ⎜µ ⎟ + µ⎜
∂y ⎝ ∂y ⎠
⎟ (6)
⎝ ∂y ⎠
The 1st term in (6) is just the velocity times the viscous net force per unit volume, so
it is the part of the total viscous work that goes to accelerate the local flow. The
second term in (6) is positive definite, and it is the rate of dissipation of energy into
heat due to viscous effects. We will return later to this heating effect.
Approximate Analysis Let us manipulate the right hand side of equation (4):
∂ ⎛ ∂u ⎞ ∂ ⎛ ∂T ⎞ ∂ ⎡ ⎛ ∂u K ∂T ⎞ ⎤
⎜ uµ ⎟+ ⎜K ⎟= ⎢µ ⎜ u + ⎟⎥
∂y ⎝ ∂y ⎠ ∂y ⎝ ∂y ⎠ ∂y ⎣ ⎝ ∂y µ ∂y ⎠ ⎦
∂h ∂T
and, since = cp , this yields
∂y ∂y
⎡ ⎛ u2 ⎞⎤
∂ ⎢ ⎜∂ 2 1 ∂h ⎟ ⎥ ⎛ µcp ⎞
µ + ⎜⎜ Pr ≡ ⎟
∂y ⎢ ⎜⎜ ∂y Pr ∂y ⎟⎟ ⎥ ⎝ k ⎟⎠
⎢⎣ ⎝ ⎠ ⎥⎦
We note here that, both for laminar and turbulent flows, Pr is a constant,
independent of P and T to a good approximation. In fact, as we noted before, it is
also of order unity ( ∼ 0.9 for turbulent flows). So, the RHS of the energy equation
becomes
∂ ⎡ ∂ ⎛ h u2 ⎞ ⎤
⎢µ ⎜ + ⎟⎥ (7)
∂y ⎢⎣ ∂y ⎜⎝ Pr 2 ⎠⎟ ⎥⎦
∂u ∂u ∂ ⎛ ∂u ⎞ ⎫
ρu + ρv = ⎜µ ⎟ ⎪
∂x ∂y ∂y ⎝ ∂y ⎠ ⎪
⎬ (8)
∂h ∂h ∂ ⎛ ∂ht ⎞⎪
ρu t + ρ v t = ⎜µ ⎟⎪
∂x ∂y ∂y ⎝ ∂y ⎠⎭
u ht − htw
u= ; h= (9)
ue hte − htw
where the ( )e subscript denotes the value of a variable in the local “external”
flow (just outside the boundary layer). Both u and h satisfy identical boundary
conditions:
uw = hw = 0; ue = he = 1 (10)
⎛ ∂P ⎞
⎜ Pr = 1, ∂x = 0 ⎟ ,
⎝ ⎠
ht − hw u
= (11)
hte − hw ue
u2w
where we also noticed htw = hw + = hw . This similarity relation between velocity
2
and total enthalpy profiles is known as Crocco’s analogy.
⎛ ∂T ⎞
qw = ⎜ K ⎟ (12)
⎝ ∂y ⎠w
⎛ K ∂h ⎞ ⎛ K ∂h ⎞
qw = ⎜ ⎟ =⎜ µ t ⎟
⎜ cp ∂y ⎟ ⎜ ⎟
⎝ ⎠w ⎝ µcp ∂y ⎠w
0, since uw = 0
⎛ ∂h ⎞ ∂ ⎛ u ⎞ 2
⎛ ∂h ⎞ ⎛ ∂h ⎞
where we used ⎜ t ⎟ = ⎜⎜ h + ⎟⎟ = ⎜ ⎟ + ⎜ u ⎟
⎝ ∂y ⎠w ∂y ⎝ 2 ⎠
w ⎝ ∂y ⎠w ⎝ ∂y ⎠w
⎛ ∂h ⎞
qw = ⎜ µ t ⎟
⎝ ∂y ⎠w
⎛ ∂ ⎡ u ⎤⎞ ht − hw ⎛ ∂u ⎞
qw = ⎜ µ
⎜ ∂y ⎢
⎣
hw + hte − hw (
⎥ ⎟ = e
ue ⎦ ⎟⎠
) ue
⎜µ ⎟
⎝ ∂y ⎠w
⎝ w
⎛ ∂u ⎞
and notice that ⎜ µ ⎟ is the wall shear stress, τw . So
⎝ ∂y ⎠w
hte − hw
qw = τw (13)
ue
which is also called Reynolds analogy. A more compact form of this can be written in
terms of the Friction Coefficient
τw
cf ≡ (14)
1
ρ u2
2 e e
qw
St = (15)
(
ρeue hte − hw )
with the result (from (13))
cf
St = (16)
2
The heat flux to the wall is driven by the enthalpy (or temperature) difference
between Total external and Wall values, not between static values. This can be non-
intuitive. Consider the situation near the exit of a highly expanded space nozzle,
where the bulk temperature Te may have dropped to, say, 300K due to the strong
expansion from a chamber temperature of, say, 3000K. The wall could be made of
Tungsten so as to be able to sustain relatively high temperature and cool itself by
radiation to space, so Tw could be, say, 1500K. Is the nozzle wall being heated or
cooled by the 300K gas? The answer is that it is being heated, because
To better understand this situation, let us return to Crocco’s analogy (equation 11)
2
and write ht = h + u , and solve for h:
2
u2
(
h = hte − hw ) uu
e
−
2
(17)
0
⎛ dh ⎞ 1 ⎛ du ⎞ ⎛ ∂u ⎞
⎜
⎝ dy ⎠w
(
⎟ = hte − hw
u
)⎜
e ⎝ dy
⎟ − ⎜u ⎟
⎠w ⎝ ∂y ⎠w
⎛ dh ⎞ ⎛ hte − hw ⎞
or ⎜ du ⎟ = ⎜⎜ u ⎟ (18)
⎝ ⎠w ⎝ ⎟
e ⎠
We can use (17) and (18) to sketch h vs. u across the boundary layer. For a case
with he > hw , this looks like
Now the wall slope is seen to be positive (heat into the wall), despite he < hw (as
long as ht > hw )
e
So, the quadratic portion of the Crocco relationship is responsible for the extra wall
heat; this can in turn be traced to viscous dissipation, which accumulates in the
boundary layer and elevates its temperature, so that the wall is heated even when
the outside temperature is low (as long as the flow has high speed).
Modification for Pr ≠ 1
We leave for now the issue of the non zero pressure gradient, except to note that it
introduces small modifications down to the throat. The deviations of Pr from unity
are small, and, for gases Pr < 1 (~ 0.9 for turbulent flow). This breaks the perfect
balance between dissipation and conduction responsible for Crocco’s analogy, in the
sense of favoring conduction of the dissipated heat. As a second consequence, the
temperature overshoot is reduced, and so is the wall slope of T and the heat flux to
the wall. The direct effect of higher conduction ( Pr < 1 ) is accounted for
approximately by modifying Reynolds analogy to
cf
St = (19)
2Pr 0.6
The secondary effect (reduced overshoot) is accounted for by replacing the driving
enthalpy difference ht − hw by haw − hw , where haw is the “Adiabatic-wall enthalpy”,
e
defined as
cf
qw = ρeue (haw − hw ) (21)
2Pr 0.6
A very crude, but surprisingly effective representation for the friction factor cf is that
supplied by the well-studied case of fully developed turbulent flow in a pipe.
0.046 ρeueD
cf = ; Re = (22)
R 0.2
e
µe
0.2
0.023 ⎛ µe ⎞ 0.026
qw = ρeuecp ( Taw − Tw ) ⎜ ⎟ = ( ρeue )0.8 µ0.2
e cp ( Taw − Tw ) (23)
Pr 0.6 ⎜⎝ ρeueD ⎟⎠ D 0.2
0.026
It is common practice to define a heat transfer “gas-side film coefficient”, hg (not an
enthalpy!) by
qw
hg ≡ (24)
Taw − Tw
0.026
hg = ( ρeue )0.8 µ0.2
e cp (25)
D0.2
At this point we note that the formulation so far has ignored the strong variations of
ρ and µ across the boundary layer since these quantities depend on temperature as
1
ρ ∼ (at P=constant) ; µ ∼ T w ( w 0.6 ) (26)
T
and <T> can be evaluated by several empirical rules. For Mach numbers not much
higher than 1, we can simply use
Te + Tw
<T> (28)
2
0.8 − 0.2w
0.026 ⎛ Te ⎞
( ρeue )
0.8
hg = ⎜ ⎟ µ0.2
e cp (29)
D0.2 ⎝< T >⎠
which is one form of Bartz’ formula. A more useful form follows from the continuity
equation:
i
m P At R g Tc
ρeue = = c , with ,
A c* A Γ (γ)
and where A is the local cross-section, and A t the throat cross-section. Substituting
2
A ⎛D ⎞
in (29), and using t = ⎜ t ⎟ , the final form is
A ⎝D⎠
⎛ 1 ⎞
(a) Smaller throat diameter leads to larger heat flux ⎜ ∼ 0.2 ⎟ . This comes
⎜ D ⎟
⎝ t ⎠
straight from the Reynolds no. dependence of cf .
(b) Heat flux is almost linear in chamber pressure ∼ Pc0.8 . This limits the ( )
feasibility of high chamber pressures, which are otherwise very desirable.
⎛ ⎛ D ⎞1.8 ⎞
(c) Maximum heat flux occurs at the throat ⎜ ∼ ⎜ t ⎟ ⎟ . One critical design
⎜ ⎝D⎠ ⎟
⎝ ⎠
consideration is therefore the thermal integrity of the throat structure.
Example
Consider the Space Shuttle Main Engine (SSME), which is a Hydrogen-Oxygen rocket
with (roughly) these characteristics:
Tc = 3600 K
M = 15g / mol
r 1.25
R g Tc
c* = 2600 m / s
Γ (γ)
γ R
cp = 2800 J / Kg / K
γ −1 M
µe 3 × 10−5 Kg / m / s
2
Tthroat = Tc 3200 K = Te
γ +1
Tw = 1000 K
We calculate then
Te + Tw 3200 + 1000
< T >= = = 2100 K (at the throat)
2 2
hg 160, 000 w / m2 / K
and qw (
160, 000 Tawt − 1000 )
1
⎛ γ −1 2⎞
( Taw )t = Tt ⎜1 + r
2
µ ⎟ = 1.057 × 3200 3400 K (slightly less than Tc )
⎝ ⎠
0.9
This is a very high level of heat flux. To visualize the implications, suppose this qw
had to be transmitted through a thin metal plate (thickness δ , thermal conductivity
k).
∆T
One would have qw = K where ∆T is the temperature drop through the metal .
δ
As an initial guess, suppose the metal were stainless steel (K 20 W / m / K ) , and
δ =1mm. Then
The St or hg should depend on x, distance from start of nozzle, since the B.L. is still
developing (not fully developed). In addition, there should be some accounting for
• acceleration
• property variation through B.L.
• cylindrical geometry
The article by Rubsin and Inonye (ch. 8 in Rosenhow and Hartnett’s Handbook of
Heat Transfer, McGraw-Hill, 1973) gives a general formula for turbulent B.L. In an
cylinder, with acceleration:
A
St ( x ) = n
(and hg = ρeuecpSt )
⎛ρu x ⎞
s ⎜ e e eff ⎟ Fc1−n FRnθ
⎝ µe ⎠
cf 2
s= 1 found walls.
ch
A⎫
⎬ = constants, depending on Reynolds no. based on mom. th.
n⎭
1
R eθ > 4000 , A = 0.0131, n =
7
1
R eθ < 4000 , A = 0.0293 , n =
5
Fc ⎫⎪
⎬ = Factors for property variability. Can take several nearly equivalent forms. A
FR θ ⎪
⎭
simple one from Eckert, is
ρe <Τ > ⎫
Fc = = ⎪
ρ (< Τ >) Te ⎪
⎪< Τ > T T
⎬ = 0.28 + 0.50 w + 0.22 aw
w ⎪ Te Te Te
µe ⎛ Te ⎞ ⎪
FRθ =
µ (< Τ >)
⎜ ⎟ (w 0.6 ) ⎪
⎝< Τ >⎠ ⎭
u2e ⎛ γ −1 2⎞
Taw = Te + r = Te ⎜ 1 + r Me ⎟
2 ⎝ 2 ⎠
The “effective distance” xeff is related to the actual distance x through an integral
(accounting for memory of past acceleration)
x f ( x ')
xeff ( x ) = ∫ dx '
0 f (x)
where f =
(
ρeue zRµne ) 1−n
n
Fc FR1 −n
θ
haw − hw ⎛ u2 ⎞
z= ⎜ haw = he + r e ⎟
hte − hw ⎜ 2 ⎟
⎝ ⎠
For a quick estimate of R eθ , we can simplify further to the flat-plate case, in which
dθ c f
= ,
dx 2
with
cf
⎧0.0128 R1 4
⎪
=⎨
eθ (R eθ < 4000 ) , and with dθ
=
dR eθ
2 ⎪0.0065 R1e 6
⎩ θ
(R eθ > 4000 ) dx dR ex
⎧ 0.0366
⎪ 0.2
R eθ θ ⎪ R ex
or = =⎨
R ex x ⎪ 0.0152
⎪ R1 7
⎩ ex
R 2t 1 R ± R 2 − R 2t
Consider nozzle R = x tan x + x=
4 tan α x 2 tan α
R c − R 2c − R 2t
with origin at x = xc =
2 tan α
Rc
and = 1.5 , α = 15o
Rt
Rt
and going through throat at x = xt =
2 tan α
xt
Rt 1.875 0.9
⎛ xeff ⎞ 5 ⎛ 1.125 ⎞ ⎛ 0.6979 ⎞ ⎛ x ⎞
⎜⎜
⎝ Rt
⎟⎟
⎠throat
= ∫
xc
M 12 ⎜⎜
⎝ 1 + 0.125M
2 ⎟⎟
⎠
⎜⎜
⎝ 0.6515 + 0.0464 M
2 ⎟⎟
⎠
d ⎜⎜
⎝ Rt
⎟⎟
⎠
Rt
1
R x 4 R
where
Rt
=
Rt
tan15o + ⇒
R
(x)
⎛ x ⎞ o t
⎜ ⎟ tan15
⎝ Rt ⎠
2.25
1 ⎛ 1 + 0.125M2 ⎞ R
and 1 ⎜ ⎟⎟ = ⇒ M (x)
⎜ 1.125 Rt
M 2⎝ ⎠
⎛x ⎞
The integration gives ⎜⎜ eff ⎟⎟ = 1.0892
⎝ R t ⎠throat
x t − xc ⎛ xc ⎞
Compared to = 1.153 ⎜⎜ and = 0.713 ⎟⎟
Rt ⎝ Rt ⎠
0.0131
(St )throat = 1
⎛ ρ u ( x t − xc ) ⎞ 7
0.771
⎛< T >⎞
⎜⎜ ⎟⎟ ⎜ ⎟
⎝ µ ⎠throat ⎝ Te ⎠throat
(3263)
(0.6952)
<T > 1000 3300
= 0.28 + 0.50 + 0.22 = 0.6979
Te 2933 2933
Take Pc = 2 × 107 N / m2 ,
M= 25 g/mol
8.314
R g Tc 3300
* 0.025
c = = 2.25
= 1592 m / s
Γ
⎛ 2 ⎞ 0.5
1.25 ⎜ ⎟
⎝ 2.25 ⎠
Pc
⇒ ( ρu ) t = *
= 12560 Kg / s / m2
c
xt 1 xc 1.5 − 1.52 − 1
= = 1.866 = = 0.7128
Rt 2 tan15o Rt 2 tan15o
0.6
⎛ T ⎞
µ 6.8 × 10−5 ⎜ ⎟ ⇒ µthroat = 6.70 × 10−5 Kg m sec
⎝ 3000 ⎠
0.0293
(St )throat =
0.2 0.68
⎛ ρ uxeff ⎞ ⎛< T >⎞
⎜ ⎟ ⎜ ⎟
⎝ µ ⎠throat ⎝ Te ⎠throat
For comparison, the “fully developed pipe flows” formulation would give
This is close to the R θ < 4000 results above (and, indeed, the coefficients are for
R θ < 4000 ). But this appears coincidental, based on the fact that for most nozzles,
∆x ∼ R t .