Table of Contents

1. Objective................................................................................................................................1

2. Introduction............................................................................................................................1

3. Methodology..........................................................................................................................2

4.Construction............................................................................................................................2

4.1. W-1209 Temperature Sensor..........................................................................................2

4.2. Mild Steel Box................................................................................................................3

4.3. Styrofoam (Insulation)....................................................................................................4

4.4. Battery.............................................................................................................................5

5. Observation and Calculation..................................................................................................6

5.1. Graphical Representation................................................................................................8

5.2. Cost Analysis for Thermal Flask Construction...............................................................8

6. Conclusion..............................................................................................................................9

7. References..............................................................................................................................9

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1. Objective

The primary objective of this project is to fabricate and evaluate the heat retention
performance of a steel vessel insulated with Styrofoam, replicating the design and
functionality of a thermal flask. The study focuses on testing the effectiveness of Styrofoam
as an insulating material in minimizing heat loss from the fabricated steel container under
ambient room conditions. By monitoring the temperature of hot water over a period of time
using a W-1209 digital temperature sensor, the project aims to gather and analyze
experimental data to determine the efficiency of the insulation system. Through this hands-on
fabrication and experimentation process, the project seeks to provide practical insights into
the design and construction of insulated containers, with the goal of optimizing heat retention
for real-world applications. The emphasis is on real-time testing without relying on
simulations, ensuring that the outcomes are directly applicable to practical usage.

2. Introduction

The need for energy-efficient systems has made insulated containers essential for applications
like thermal storage and food preservation. This project focuses on fabricating a steel vessel
insulated with Styrofoam, designed to function as a thermal flask. The aim is to test the
vessel's ability to retain heat and reduce energy loss under ambient conditions.

Mild steel is used for its durability and structural integrity, while Styrofoam, with its low
thermal conductivity, minimizes heat transfer. The heat loss in this setup primarily occurs
through conduction, where heat travels through the steel walls, convection, as the hot water
exchanges heat with the air inside the container, and radiation from the vessel's outer surface.
Styrofoam insulation acts as a barrier to both conduction and convection, reducing heat
transfer effectively.

The temperature changes of water, initially at 92°C, are monitored using a W-1209 digital
temperature sensor powered by a 9V battery. This hands-on experiment evaluates the real-
world performance of the fabricated vessel without relying on simulations, offering practical
insights into thermal insulation. The results will help optimize the design of energy-efficient
thermal flasks by addressing heat transfer mechanisms directly.

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3. Methodology

Heat transfer is the process by which thermal energy moves from a region of higher
temperature to a region of lower temperature. This can occur through conduction, convection,
and radiation. When hot water is poured into a mild steel rectangular box insulated with
Styrofoam, heat transfer to the surroundings happens through several stages involving these
mechanisms.

First, conduction occurs as heat transfers directly from the hot water to the inner surface of
the mild steel box due to their physical contact. The heat then conducts through the mild steel
walls of the box, albeit slowly, as steel has relatively low thermal conductivity compared to
other metals. Next, the heat moves to the Styrofoam insulation layer through conduction.
However, this process is significantly impeded because Styrofoam is an excellent thermal
insulator with very low thermal conductivity. Within the Styrofoam, a small amount of heat is
transferred via natural convection in the air-filled cells that form its structure, although this
transfer is minimal. Overall, the combined insulation properties of the steel box and
Styrofoam significantly reduce heat loss to the surroundings, retaining the heat of the water
for a longer period.

4.Construction

The project consists of following parts

 W-1209 Temperature Sensor
 Mild Steel Box
 Styrofoam (Insulation)
 9V Battery

4.1. W-1209 Temperature Sensor

W-1209 is a compact and affordable digital temperature controller often used for monitoring
and controlling temperature in various applications. It comes with a thermistor-based
temperature sensor (commonly NTC), allowing it to detect temperatures accurately within a
specified range. It features an LED display for real-time temperature readings and control
buttons to set the desired temperature thresholds.

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Sensor Range: The W-1209 typically operates within a range of -50°C to +110°C, suitable
for applications involving moderate temperature changes.

Accuracy: The sensor's accuracy directly impacts how well heat transfer rates can be
monitored. Typical accuracy ranges from ±0.1°C to ±1°C, depending on the configuration.

Response Time: The sensor's ability to quickly adapt to temperature changes determines
how effectively it tracks dynamic heat transfer processes.

FIGURE 1: TEMPRATURE SENSOR

4.2. Mild Steel Box

A mild steel box is a container made from low-carbon steel, valued for its strength and
affordability. In thermal applications, mild steel exhibits moderate thermal conductivity,
which means it can transfer heat, but at a slower rate than materials like aluminum or copper.

Thermal Conductivity (k): For mild steel, k ≈ 50 W/m·K, meaning it conducts heat
moderately but much slower than highly conductive metals.

Wall Thickness: Thicker walls increase the resistance to heat transfer, reducing the rate at
which heat moves through the steel.

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Surface Area: A larger surface area enhances heat transfer between the mild steel and its
surroundings.

FIGURE 2: STEEL BOX

4.3. Styrofoam (Insulation)
Styrofoam is a lightweight, porous material often used as thermal insulation due to its very
low thermal conductivity. It consists of trapped air pockets that significantly hinder heat
transfer by conduction and convection.

Thermal Conductivity (k): For Styrofoam, k ≈ 0.03 W/m·K, making it an excellent

insulator.

Thickness: A thicker Styrofoam layer provides greater resistance to heat transfer, reducing
heat loss.

Density and Air Content: The trapped air content and density influence its insulating
properties; higher air content improves insulation.

Surface Area and Fit: Proper coverage ensures minimal heat transfer paths, optimizing
insulation effectiveness.

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 FIGURE 3: STYROFOAM
4.4. Battery
A 9V DC battery is a common type of battery often used in small electronic devices. It
provides a constant direct current (DC) voltage of 9 volts. These batteries are typically
composed of six 1.5V cells connected in series, which deliver power to devices like smoke
detectors, radios, and handheld electronics. The 9V battery is compact, lightweight, and
designed for low-power applications. While it has a relatively short lifespan compared to
larger batteries, it is widely available and inexpensive.

FIGURE 4: 9V DC BATTERRY

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Construction Steps

Prepare the Mild Steel Box: Clean the box thoroughly and drill holes for the W-1209 sensor
and wiring. Seal any gaps or edges with waterproofing sealant to prevent heat or liquid
leakage.

Attach Styrofoam Insulation: Cut Styrofoam sheets to match the dimensions of the box.
Securely attach them to the outer surfaces using high-temperature adhesive, ensuring full
coverage and sealing all edges.

Install the W-1209 Temperature Sensor: Place the sensor probe inside the box to monitor
temperature and mount the controller outside. Connect the wiring according to the
controller’s diagram and power it.

Test the System: Pour hot water into the box, monitor the temperature readings, and check
for heat loss. Seal any observed gaps in the insulation

5. Observation and Calculation

Temperature Difference (ΔT)

74.4°C +25℃= 49.4℃

67.5°C + 25℃= 42.5℃

60.3°C + 25℃ = 35.3℃

54.5°C + 25 ℃= 29.5℃

50.2°C + 25℃ = 25.2℃

46.7°C + 25℃ = 21.7℃

Heat loss (Q)

KA(T 1−T 2)
Q= d
Where:

k = 0.03 W/m·K (thermal conductivity of Styrofoam)

A= 0.557 m² (calculated surface area of the box)

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T1= temperature of the water

T2= room temperature = 25°C

d = 1.5 inches = 0.0381 m (thickness of Styrofoam)

0.03 ×0.557 × ( 74.4−25 )

Q 1= =21.7 W
0.0381
0.03 ×0.557 × ( 67.5−25 )
Q 2= =18.6 W
0.0381
0.03 ×0.557 × ( 60.3−25 )
Q 3= =15.5W
0.0381
0.03× 0.557 × ( 54.5−25 )
Q4 = =12.9 W
0.0381
0.03 ×0.557 × ( 50.2−25 )
Q 5= =11.1W
0.0381
0.03 × 0.557 × ( 46.7−25 )
Q 6= =9.5W
0.0381

Values Table

TABLE 1: EXPERIMENTAL VALUES

Sr No Time Temperature Temperature Diff Heat loss

(minutes) (℃) (℃) (W)
1 0 74.4 49.4 21.7
2 60 67.5 42.5 18.6
3 120 60.3 35.3 15.5
4 180 54.5 29.5 12.9
5 240 50.2 25.2 11.1
6 300 46.7 21.7 9.5

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5.1. Graphical Representation
The graphical trend is shown in graph 1 in which on:

X-axis (Time in seconds)

Y-axis (Temperature in Celsius)

Temperature ( ℃ ) vs Time (Min)

80 74.4
67.5
70
60.3
60 54.5
Temprature (C)

50.2
50 46.7

40

30

20

10

0
0 60 120 180 240 300

Time (miin

GRAPH 1 :OBSERVED TEMPERATURE VS TIME

5.2. Cost Analysis for Thermal Flask Construction

TABLE 2: COST ANALYSIS

Component Quantity Price (Rs)

Steel vessels 1 2000
Styrofoam Sufficient for gap 200
9V DC battery 1 150
Temperature Sensors 1 400
Wiring,adhesive etc. 1 300

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Total Estimated Cost: Rs 2900

6. Conclusion

In conclusion, the heat loss analysis of the water in the insulated mild steel box demonstrates
that the temperature of the water decreases steadily over time, with heat loss being influenced
by the insulation properties and the temperature difference between the water and the
surrounding environment. As the temperature difference reduces, the rate of heat loss also
decreases. The use of Styrofoam insulation effectively slows down the rate of heat transfer,
though the loss of heat remains significant due to the initial high temperature of the water.
This experiment highlights the importance of insulation in reducing energy loss in
thermal systems.

7. References

[1] Experimental Heat Transfer, Fluid Mechanics, and Thermodynamics, Editors: M.

Perlmutter, B. Sunden

[2] Incropera_Fundamentals_Heat_Mass_Transfer_7th Edition

[3] https://youtu.be/xLlBpXJcAps?si=9IHrpzva3xhLIxkI