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Design and Optimization

of Thermal Systems

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Design and Optimization of Thermal Systems, Third Edition,

with MATLAB® Applications
Yogesh Jaluria

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Design and Optimization

of Thermal Systems
Third Edition
With MATLAB® Applications

Yogesh Jaluria

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Library of Congress Cataloging‑in‑Publication Data

Names: Jaluria, Yogesh, author.

Title: Design and optimization of thermal systems / Yogesh Jaluria.
Description: Third edition. | Boca Raton, FL : CRC Press/Taylor & Francis Group, 2020. |
Series: Mechanical engineering | Includes bibliographical references and index.
Identifiers: LCCN 2019018480| ISBN 9781498778237 (hardback : acid-free paper) |
ISBN 9780429085789 (ebook)
Subjects: LCSH: Heat engineering. | Heat engineering—Instruments. | Engineering design.
Classification: LCC TJ260 .J353 2020 | DDC 621.402—dc23
LC record available at https://lccn.loc.gov/2019018480

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Contents
Preface to the First Edition .............................................................................................................. xv
Preface to the Third Edition ...........................................................................................................xix
Author .............................................................................................................................................xxi

Chapter 1 Introduction .................................................................................................................. 1

1.1 Engineering Design ...........................................................................................1
1.1.1 Design versus Analysis.........................................................................2
1.1.2 A Few Examples...................................................................................3
1.1.3 Synthesis for Design ............................................................................. 4
1.1.4 Selection versus Design ........................................................................5
1.2 Design as Part of Engineering Enterprise ......................................................... 7
1.2.1 Need or Opportunity ............................................................................7
1.2.2 Evaluation and Market Analysis ..........................................................8
1.2.3 Feasibility and Chances of Success...................................................... 9
1.2.3.1 Measure of Success............................................................. 9
1.2.3.2 Chances of Success .............................................................9
1.2.3.3 Feasibility ......................................................................... 11
1.2.4 Engineering Design ............................................................................ 11
1.2.5 Research and Development ................................................................ 12
1.2.6 Need for Optimization ....................................................................... 13
1.2.7 Fabrication, Testing, and Production .................................................. 13
1.3 Thermal Systems ............................................................................................. 16
1.3.1 Basic Characteristics .......................................................................... 16
1.3.2 Analysis .............................................................................................. 17
1.3.3 Types and Examples ...........................................................................20
1.3.3.1 Manufacturing and Materials Processing Systems ..........20
1.3.3.2 Energy Systems ................................................................ 21
1.3.3.3 Cooling Systems for Electronic Equipment ..................... 23
1.3.3.4 Environmental and Safety Systems ..................................24
1.3.3.5 Aerospace Systems ...........................................................26
1.3.3.6 Transportation Systems ....................................................26
1.3.3.7 Air Conditioning, Refrigeration, and
Heating Systems ............................................................... 27
1.3.3.8 Fluid Flow Systems and Equipment .................................28
1.3.3.9 Heat Transfer Equipment .................................................. 29
1.3.3.10 Other Systems ................................................................... 31
1.4 Outline and Scope of the Book ....................................................................... 31
1.4.1 A Note on Problems and Examples.................................................... 33
1.5 Summary ......................................................................................................... 33
References ..................................................................................................................34

Chapter 2 Basic Considerations in Design .................................................................................. 37

2.1 Formulation of the Design Problem ................................................................ 37
2.1.1 Requirements and Specifications ....................................................... 37

v
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vi Contents

2.1.1.1 Specifications .................................................................... 39

2.1.2 Given Quantities ................................................................................. 39
2.1.3 Design Variables ................................................................................40
2.1.3.1 Hardware .......................................................................... 41
2.1.3.2 Operating Conditions........................................................ 41
2.1.4 Constraints or Limitations.................................................................. 42
2.1.5 Additional Considerations .................................................................. 43
2.2 Conceptual Design .......................................................................................... 45
2.2.1 Innovative Conceptual Design ...........................................................46
2.2.1.1 An Example ......................................................................46
2.2.2 Selection from Available Concepts .................................................... 48
2.2.3 Modifications in the Design of Existing Systems .............................. 50
2.3 Steps in the Design Process ............................................................................. 54
2.3.1 Physical System .................................................................................. 56
2.3.2 Modeling ............................................................................................ 57
2.3.3 Simulation .......................................................................................... 59
2.3.3.1 An Example ...................................................................... 61
2.3.4 Evaluation: Acceptable Design .......................................................... 63
2.3.5 Optimal Design .................................................................................. 65
2.3.5.1 Examples...........................................................................66
2.3.6 Safety Features, Automation, and Control ......................................... 67
2.3.7 Communicating the Design ................................................................ 69
2.3.8 Patents and Copyrights ....................................................................... 71
2.4 Computer-Aided Design .................................................................................. 76
2.4.1 Main Features..................................................................................... 76
2.4.2 Computer-Aided Design of Thermal Systems ................................... 77
2.5 Material Selection............................................................................................ 81
2.5.1 Different Materials ............................................................................. 82
2.5.2 Material Properties and Characteristics for
Thermal Systems ................................................................................ 85
2.5.3 Selection and Substitution of Materials.............................................. 86
2.5.3.1 Final Comments................................................................ 88
2.6 Summary ......................................................................................................... 89
References ..................................................................................................................90
Problems ..................................................................................................................... 91

Chapter 3 Modeling of Thermal Systems ...................................................................................97

3.1 Introduction .....................................................................................................97
3.1.1 Importance of Modeling in Design ....................................................97
3.1.2 Basic Features of Modeling................................................................97
3.2 Types of Models ..............................................................................................99
3.2.1 Analog Models ................................................................................. 100
3.2.2 Mathematical Models ....................................................................... 100
3.2.3 Physical Models................................................................................ 101
3.2.4 Numerical Models ............................................................................ 101
3.2.5 Interaction between Models ............................................................. 102
3.2.6 Other Classifications ........................................................................ 103
3.3 Mathematical Modeling ................................................................................ 104
3.3.1 General Procedure............................................................................ 104
3.3.1.1 Transient/Steady State .................................................... 104

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Contents vii

3.3.1.2 Spatial Dimensions ......................................................... 107

3.3.1.3 Lumped Mass Approximation ........................................ 109
3.3.1.4 Simplification of Boundary Conditions .......................... 110
3.3.1.5 Negligible Effects ........................................................... 111
3.3.1.6 Idealizations .................................................................... 112
3.3.1.7 Material Properties ......................................................... 112
3.3.1.8 Conservation Laws ......................................................... 113
3.3.1.9 Further Simplification of the
Basic Equations............................................................... 115
3.3.1.10 Summary ........................................................................ 116
3.3.2 Final Model and Validation .............................................................. 125
3.4 Physical Modeling and Dimensional Analysis .............................................. 128
3.4.1 Scale Up ........................................................................................... 129
3.4.2 Dimensional Analysis ...................................................................... 129
3.4.3 Modeling and Similitude .................................................................. 138
3.4.3.1 Geometric Similarity ...................................................... 138
3.4.3.2 Kinematic Similarity ...................................................... 138
3.4.3.3 Dynamic Similarity ........................................................ 139
3.4.3.4 Thermal Similarity ......................................................... 139
3.4.3.5 Mass Transfer Similarity ................................................ 140
3.4.4 Overall Physical Model .................................................................... 140
3.5 Curve Fitting.................................................................................................. 141
3.5.1 Exact Fit ........................................................................................... 141
3.5.2 Best Fit.............................................................................................. 145
3.5.2.1 Linear Regression ........................................................... 146
3.5.2.2 Polynomial Best Fit ........................................................ 147
3.5.2.3 Nonpolynomial Forms and Linearization ...................... 148
3.5.2.4 More than One Independent Variable............................. 149
3.3.2.5 Concluding Remarks ...................................................... 150
3.6 Summary ....................................................................................................... 153
References ................................................................................................................ 154
Problems ................................................................................................................... 154

Chapter 4 Numerical Modeling and Simulation ....................................................................... 163

4.1 Numerical Modeling...................................................................................... 163
4.1.1 General Features .............................................................................. 164
4.1.1.1 Accuracy and Validity of
the Model ........................................................................ 165
4.1.2 Development of a Numerical Model ................................................ 165
4.1.3 Available Software ........................................................................... 166
4.2 Solution Procedures ....................................................................................... 167
4.2.1 Linear Algebraic Systems ................................................................ 167
4.2.1.1 Direct Methods ............................................................... 168
4.2.1.2 Iterative Methods ............................................................ 170
4.2.2 Nonlinear Algebraic Systems ........................................................... 173
4.2.2.1 Single Nonlinear Algebraic Equation ............................. 173
4.2.2.2 System of Nonlinear Algebraic Equations ..................... 178
4.2.3 Ordinary Differential Equations ...................................................... 179
4.2.3.1 Initial-Value Problems .................................................... 179
4.2.3.2 Boundary-Value Problems .............................................. 184

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viii Contents

4.2.4 Partial Differential Equations .......................................................... 188

4.2.4.1 Finite-Difference Method ............................................... 189
4.2.4.2 Finite-Element Method ................................................... 191
4.2.4.3 Other Methods ................................................................ 193
4.3 Numerical Model for a System ...................................................................... 195
4.3.1 Modeling of Individual Components ............................................... 196
4.3.1.1 Isolating System Parts .................................................... 196
4.3.1.2 Mathematical Modeling.................................................. 196
4.3.1.3 Numerical Modeling ....................................................... 197
4.3.2 Merging of Different Models ........................................................... 198
4.3.3 Accuracy and Validation .................................................................. 199
4.4 System Simulation .........................................................................................200
4.4.1 Importance of Simulation.................................................................200
4.4.1.1 Evaluation of Design....................................................... 201
4.4.1.2 Off-Design Performance and
Safety Limits................................................................... 201
4.4.1.3 Optimization ................................................................... 201
4.4.1.4 Modifications in Existing Systems .................................202
4.4.1.5 Sensitivity .......................................................................202
4.4.2 Different Classes ..............................................................................202
4.4.2.1 Dynamic or Steady State ................................................202
4.4.2.2 Continuous or Discrete ................................................... 203
4.4.2.3 Deterministic or Stochastic ............................................204
4.4.3 Flow of Information .........................................................................204
4.4.3.1 Block Representation ......................................................205
4.4.3.2 Information Flow ............................................................205
4.5 Methods for Numerical Simulation ...............................................................208
4.5.1 Steady Lumped Systems ..................................................................208
4.5.1.1 Successive Substitution Method .....................................208
4.5.1.2 Newton-Raphson Method ...............................................209
4.5.2 Dynamic Simulation of Lumped Systems........................................ 215
4.5.2.1 Analytical Solution ......................................................... 215
4.5.2.2 Numerical Solution ......................................................... 217
4.5.3 Distributed Systems.......................................................................... 220
4.5.3.1 Linearization ................................................................... 221
4.5.4 Simulation of Large Systems............................................................ 222
4.5.5 Numerical Simulation versus Real System ...................................... 223
4.6 Summary .......................................................................................................224
References ................................................................................................................ 225
Problems ................................................................................................................... 225

Chapter 5 Acceptable Design of a Thermal System: A Synthesis of

Different Design Steps ............................................................................................. 235
5.1 Introduction ................................................................................................... 235
5.2 Initial Design ................................................................................................. 236
5.2.1 Selection of Components .................................................................. 237
5.2.2 Existing Systems .............................................................................. 238
5.2.3 Library of Previous Designs............................................................. 238
5.2.4 Expert Knowledge ............................................................................ 239
5.3 Design Strategies ........................................................................................... 243

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Contents ix

5.3.1 Commonly Used Design Approach.................................................. 243

5.3.2 Other Strategies ................................................................................ 243
5.3.2.1 Adjusting Design Variables ............................................ 243
5.3.2.2 Different Designs ............................................................ 243
5.3.2.3 Examples......................................................................... 243
5.3.2.4 Selection of Acceptable Design ...................................... 247
5.3.3 Iterative Redesign Procedure ........................................................... 249
5.3.3.1 Convergence.................................................................... 249
5.3.3.2 System Redesign ............................................................. 251
5.4 Design of Systems from Different Application Areas .................................. 253
5.4.1 Manufacturing Processes ................................................................. 253
5.4.2 Cooling of Electronic Equipment..................................................... 258
5.4.3 Environmental Systems .................................................................... 263
5.4.4 Heat Transfer Equipment ................................................................. 269
5.4.4.1 Modeling and Simulation ............................................... 269
5.4.4.2 Design Problem............................................................... 271
5.4.5 Fluid Flow Systems .......................................................................... 275
5.4.5.1 Selection of Equipment ................................................... 276
5.4.5.2 Piping Systems................................................................280
5.4.6 Other Areas ...................................................................................... 282
5.4.7 Design of Components versus Design
of Systems ........................................................................................ 283
5.5 Additional Considerations for Large Practical
Systems .......................................................................................................... 285
5.5.1 Other Large Systems ........................................................................ 291
5.5.2 Inverse Problems .............................................................................. 293
5.5.3 Uncertainties .................................................................................... 294
5.6 Summary ....................................................................................................... 295
References ................................................................................................................ 296
Problems ................................................................................................................... 297

Chapter 6 Economic Considerations ......................................................................................... 303

6.1 Introduction ................................................................................................... 303
6.2 Calculation of Interest ...................................................................................304
6.2.1 Simple Interest ..................................................................................304
6.2.2 Compound Interest ........................................................................... 305
6.2.3 Continuous Compounding................................................................306
6.2.4 Effective Interest Rate ......................................................................306
6.3 Worth of Money as a Function of Time ........................................................308
6.3.1 Present Worth ...................................................................................309
6.3.2 Future Worth .................................................................................... 310
6.3.3 Inflation ............................................................................................ 311
6.4 Series of Payments......................................................................................... 313
6.4.1 Future Worth of Uniform Series of Amounts .................................. 314
6.4.2 Present Worth of Uniform Series of Amounts ................................. 314
6.4.3 Continuous Compounding in a Series of Amounts .......................... 316
6.4.4 Changing Amount in Series of Payments ........................................ 317
6.4.5 Shift in Time .................................................................................... 318
6.4.6 Different Frequencies ....................................................................... 319
6.4.7 Changes in Schedule ........................................................................ 320

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