Finite Element Analysis of Heat Transfer in Single and Double Walled Beverage Containers by Peter Tu An Engineering Project Submitted to the Graduate Faculty of Rensselaer Polytechnic Institute in Partial Fulfillment of the Requirements for the degree of MASTER OF ENGINEERING Major Subject: Mechanical Engineering Approved: _________________________________________ Professor Ernesto Gutierrez-Miravete, Project Adviser Rensselaer Polytechnic Institute Hartford, Connecticut December, 2014 i © Copyright 2014 by Peter Tu All Rights Reserved ii CONTENTS LIST OF TABLES ............................................................................................................ iv LIST OF FIGURES ........................................................................................................... v KEYWORDS .................................................................................................................... vi SYMBOLS ...................................................................................................................... vii ACKNOWLEDGMENT ................................................................................................ viii ABSTRACT ..................................................................................................................... ix 1. INTRODUCTION ......................................................................................................... 1 2. THEORY & METHODOLOGY ................................................................................... 2 2.1 Theory .................................................................................................................... 2 2.2 Methodology .......................................................................................................... 3 3. RESULTS & DISCUSSION ......................................................................................... 7 3.1 COMSOL Heat Transfer in Solids Model – Single Walled Cup........................... 9 3.2 COMSOL Heat Transfer in Solids Model – Double Walled Cup ....................... 14 4. Conclusions.................................................................................................................. 19 5. References.................................................................................................................... 20 6. Appendices .................................................................................................................. 21 iii LIST OF TABLES Table 1: Material property constants or relationships used in the thermal analysis models Table 2: Mesh convergence study results iv LIST OF FIGURES Figure 1: Left - Single walled cup [5]; Right - Double walled cup [6] Figure 2: Schematic of the heat transfer process: 1. Thermal conduction through inner wall, 2. Convection via trapped gas, 3. Thermal conduction through outer wall, 4. Energy lost to environment Figure 3: Thermal model boundary conditions Figure 4: Kiran Tea Glass by Teavana Figure 5: Scale, digital caliper, and radius gages Figure 6: Cross-section of the 3D models of the cup, air, and water Figure 7: The cup, air, and water domains after importing and repairing in COMSOL Figure 8: Thermal model at time = 30 minutes in COMSOL Figure 9: Plot of the water and single walled glass cup temperature against time Figure 10: Double walled cup thermal model at time = 30 minutes Figure 11: Plot of the water and double walled glass cup temperature against time Figure 12: Measured temperature of boiled water versus time in the Kiran Tea Glass Figure 13: Graph of the temperature of boiled water in the Kiran Tea Glass v KEYWORDS Singled walled cup, double walled cup, transient heat transfer, conjugate heat transfer, axisymmetric, natural convection, heat transfer in solids, borosilicate glass, NX, COMSOL vi SYMBOLS π = thermal conductivity of the material (π ⁄π β πΎ) β = βπππ (πΏ, ππ΄ , πππ₯π‘ ) (π ⁄π2 β πΎ) L = plate height, length, or diameter (m) ππ΄ = Absolute pressure (Pa) πππ₯π‘ = Externals temperature (K) π = Energy added to the system (J) t = time (s) π = material density (kg/π3 ) πΆπ = heat capacity at constant pressure (π½/(ππ β πΎ) vii ACKNOWLEDGMENT I would like to acknowledge my family for their constant support and encouragement throughout my career and studies. I would also like to acknowledge Professor Ernesto Gutierrez-Miravete for his guidance and council as I conducted this final study. viii ABSTRACT This project documents the analytical simulations that were created along with the collection of data to confirm the validity of the claim that double walled beverage cups keep hot liquids hotter for longer periods of time than single walled cups. Thermal models of single walled and double walled cups of the same geometry were generated to study and compare the behavior of the two systems. The thermal models feature conduction heat transfer in solids with natural convection boundaries. The circulation cells that occur in liquid water and gases were not modeled in these studies. The double walled glass cup thermal model was also updated to mimic the data collection activity that occurred to see how well the model could predict the behavior of an actual test specimen. The project concludes in support of the claim that double walled cups keep hot liquids hot longer than single walled cups of similar geometry. Further refinements to the thermal models and potential uses are also offered for future reference. ix 1. INTRODUCTION The traditional cup is typically a single walled container formed to hold liquids. Rapid loss or gain of thermal energy by the liquid depends on the cup geometry and materials used. Handles are often added to cups as a feature to enable usage without exposing the user to hot surfaces [1,2]. The desire for cups that are less prone to rapid heat transfer has been addressed by the invention of double walled cups. The first double walled cup patent was issued on July 22, 1969 under number 3456860 to William L. Janninck [3,4]. The original design featured plastic inner and outer walls supported by circumferential and axial ribs that maintained structural integrity of the cup while minimizing heat transfer from the inner to outer wall. Modern day double walled cups can be fabricated from various materials and are delivered in many shapes and sizes. Figure 1 depicts a typical single walled cup next to a typical modern day double walled cup. Figure 1: Left - Single walled cup [5]; Right - Double walled cup [6] Based on similarity of double walled beverage cups to double paned windows, double walled cups are expected to keep hot liquids hot longer than single walled cups. The feature that makes double walled cups similar to double paned windows is the layer of trapped gas between the inner and outer walls. 1 2. THEORY & METHODOLOGY Double walled beverage cups are promoted as being able to keep hot drinks hot and cold drinks cold for longer periods of time than single walled beverage cups. Much like double pane windows, double walled mugs capture an insulating layer of air between two layers of material and prevent thermal energy from being readily conducted through to the other side. 2.1 Theory The process of heat transfer can be simplified as follows and is depicted in Figure 2: 1. The inner most wall of the window obtains thermal energy and transfers the energy to towards the second wall via thermal conduction 2. The gas in between the two walls then transfer the thermal energy to the second wall through convection 3. The energy is then conducted through the second wall 4. Lost to the environment via convection Figure 2: Schematic of the heat transfer process: 1. Thermal conduction through inner wall, 2. Convection via trapped gas, 3. Thermal conduction through outer wall, 4. Energy lost to environment 2 2.2 Methodology Heat transfer is a process where thermal energy is exchanged between neighboring systems in response to a temperature difference [7]. This is in accordance to conservation of energy theory where the total energy of an isolated system remains constant and the first law of thermodynamics where the change in internal energy of a system is equal to the heat added to the system minus the work done by the system [7]. The heat transfer process is categorized into three modes: conduction, convection, and radiation. Heat conduction is heat transfer across a medium without any motion of the material as a whole [4]. In a solid, the mechanism of conduction is the atomic activity in the form of lattice vibration which contribution of the translational motion of electrons if the solid is electrically-conducting. Heat conduction in a liquid or gas is due to the random motion and interaction of the molecules. Examples of conductive heat transfer: the transfer of heat energy down the axis of a metal rod when one end is a higher temperature than the other; and the transfer of heat energy from a stove element through a metal pan into the contents within. Convective heat transfer occurs between systems by moving fluid past a wall of a different temperature. Convection can be forced or natural - for the purposes of this discussion and project, only natural will be described and used in the analysis model. Natural convection occurs in accordance to the Ideal Gas Law, where a liquid that increases in temperature also decreases in density and rises [7]. Due to the resulting internal buoyancy force, circulating currents then transport the heat energy away from the energy source. For the purposes of this study, only natural convection heat transfers from the cup and water surfaces exposed to the surrounding environment were simulated. To simplify the heat transfer model and to avoid any complications with a conjugate heat transfer model, the heat transfer where the interfaces between the water, cup, and air gap were analyzed 3 as time dependent conductive heat transfer in solids. These simplifications were necessary to demonstrate that the thermal models were well behaved and that the inputs or model geometry did not influence the calculations and predictions. The equation for time dependent heat transfer in solids is as follows: ππΆπ ππ = ∇ β (π∇π) + π ππ‘ Where: π = Energy added to the system (J) t = time (s) π = thermal conductivity of the material (π ⁄π β πΎ) π = material density (kg/π3 ) π = temperature (K) πΆπ = heat capacity at constant pressure (π½/(ππ β πΎ) The convective heat transfer boundary conditions in this study were simplified into natural convection from a horizontal and vertical plate. The assumption is that the cup is on a level surface and the cup geometry can be approximated by a vertical wall. For a time dependent study, the natural convection across a vertical or horizontal plate is represented by the following equation: −π β (−π∇π) = β β (πππ₯π‘ − π) Where: β = βπππ (πΏ, ππ΄ , πππ₯π‘ ) (π ⁄π2 β πΎ) L = plate height, length, or diameter (m) ππ΄ = Absolute pressure (Pa) πππ₯π‘ = External temperature (K) 4 Thermal radiation is a form of energy emitted by matter at a nonzero temperature and can be considered to be the propagation of electromagnetic waves or particles. For the purpose of this project, this form of heat transfer will be considered insignificant. Using the above equations to generate the boundary conditions that will be applied to the thermal models results in the following Figure 3. Figure 3: Thermal model boundary conditions The material properties used in this work were taken from the COMSOL built-in materials library. Table 1 provides the values for each property. The material properties for air and liquid water are temperature dependent; therefore no single value is listed in the table. 5 Silica Glass Property Name Heat Capacity at constant pressure Cp Density rho Thermal conductivity k Air Property Name Heat Capacity at constant pressure Cp Density rho Thermal conductivity k Water, liquid Property Name Heat Capacity at constant pressure Cp Density rho Thermal conductivity k Value 703 2203 1.38 Units J/(kg*K) kg/m^3 W/(m*K) Value Cp(T[1/K]) rho(pA[1/Pa],T[1/K]) k(T[1/K]) Units J/(kg*K) kg/m^3 W/(m*K) Value Cp(T[1/K]) rho(T[1/K]) k(T[1/K]) Units J/(kg*K) kg/m^3 W/(m*K) Table 1: Material properties used in the thermal analysis models 6 3. RESULTS & DISCUSSION The test specimen obtained for this project is the Kiran Tea Glass distributed exclusively by Teavana [8]. The cup is double walled, made from borosilicate glass, and holds 8 ounces or 235 milliliters of liquid. The cup can be procured from any Teavana retail store or from the company’s internet website. Figure 4 is a picture of the cup. Figure 4: Kiran Tea Glass by Teavana The reason for selecting this cup model is due to its design being simple, axisymmetric, and being made from a clear glass material. This simplifies not only the analysis, but also eliminates complications from the analysis model. A two-dimensional sketch of the cup was created using NX 6.0, the computer-aided design software package formerly known as NX Unigraphics. The inputs used to model the cup were gathered using a scale, digital caliper, and radius gages. Dimensions that 7 could not be measured such as the thickness of the glass were estimated. Also, flaws in the glass itself like bubbles or uneven surface profiles were not incorporated into the model. All dimensions were gathering in the United States customary system units then converted to metric using NX. Figure 5 is a picture of the tools used to gather the dimensions of the cup being analyzed. Figure 5: Scale, digital caliper, and radius gages To facilitate the analysis model, two-dimensional sketches of the water and air were created using the curves from the two-dimensional cup sketch. As with the cup, the air and water were created in the United States customary system units then converted to metric using NX. Imperfections such as uneven wall profiles and scratches were not incorporated into the model. 8 These sketches were then revolved around a datum axis to generate a three dimensional model. The following Figure 6 is a picture of the three models nested and crosssectioned. Figure 6: Cross-section of the 3D models of the cup, air, and water While the three-dimensional models of the cup, air, and water were not necessary for the study, they were useful for predicting what the two-dimensional-axisymmetric thermal model would look like based on the two-dimensional NX model. 3.1 COMSOL Heat Transfer in Solids Model – Single Walled Cup COMSOL Multiphysics 4.2a was used to create and solve the finite element analysis models for both the single walled and double walled cup. Since the two models are geometrically the same, the procedure used to create and set up the thermal analysis was common for both models. The geometry created using NX was imported into COMSOL via a Drawing Exchange Format (DXF) file which is one of the default export files from NX. The heat transfer module was then used to generate time-dependent Heat Transfer in Solids studies and apply the boundary conditions. The COMSOL mesh generator and analysis solver were used to set up the remainder of the simulations. 9 After importing, the cup, air, and water geometry were united and repaired to compensate for any approximations that were made when the NX files were converted to the appropriate measurement systems and file formats. The relative repair tolerance function in COMSOL was utilized to perform the geometry repair. The repair tolerance was set to 1e-3 millimeters. Figure 7 is a picture of the cup, air, and water domains after being imported and repaired in COMSOL. Figure 7: The cup, air, and water domains after importing and repairing in COMSOL For the single walled cup thermal study, the air domain was set to the same material properties as the cup domain. This eliminated any potential analytical discrepancies a single walled cup of different geometry would have when drawing comparison conclusions between single and double walled cups. The material property values for the glass and water were from the built-in library in COMSOL. 10 The thermal models are two-dimensional axisymmetric. It is important to note that utilizing an axis of symmetry simplifies the thermal model by eliminating the need to account for any uneven heat transfer perpendicular to the axis of symmetry and the amount of detail that needed to be taken into account when generating the 2D sketch in NX. In heat transfer in solids models, any curves between materials are set to conductive heat transfer by default. Insulating boundary conditions were added to the bottom and axis of symmetry. Natural convection boundary conditions were added to the top of the water and outer wall of the cup. Refer to Figure 4 an overall sketch of the boundary conditions and their ruling equations. Zero heat energy is lost to the surrounding environment from the while normal convection heat transfer occurs at the sides and top surface of the water. Convection past a vertical wall were applied to the sides of the of the glass cup model. Convection past a horizontal plate was applied to the exposed surface of the water model. In both natural convection boundary conditions the atmospheric pressure and temperature were set to 1 atm and 293.15 K, respectively. The initial temperature value of the water was set to 373.15 Kelvin. The initial temperature value of the cup was set to 294.26 Kelvin. This would simulate boiled water added to the single walled glass cup at room temperature. The rest of the variables in the thermal equations are satisfied by the material properties and their temperature dependent relationships listed in Table 1. COMSOL offers the user the opportunity to use meshes of incrementing coarseness. In order to confirm that the thermal model would not be influenced by the mesh, a mesh coverage study was performed. Based on the convergence study, the mesh size bears no influence on the calculations and a mesh of normal element size would be appropriate for this study. The following Table 2 displays the results of the convergence study. 11 Element Size Extremely Coarse Extra Coarse Coarser Coarser Normal Fine Finer Extra Fine Extremely Fine Element Count Degrees of Freedom Final Water Temp (K) 725 862 1139 1685 2544 2645 3621 5917 18078 1534 1813 2380 3500 5255 5462 7442 12082 36595 351.3 351.65 351.22 352.03 351.89 351.8 351.8 352.14 352.27 Table 2: Mesh convergence study results The thermal model for the single walled glass cup is a time dependent study. The study duration was for thirty minutes and with each solver step size no larger than 60 seconds. Figure 8 is a picture of the single walled glass cup thermal model at time = thirty minutes in COMSOL. Figure 8: Thermal model at time = 30 minutes in COMSOL 12 After thirty minutes, the water temperature dropped approximately 22 degrees and the cup temperature rose approximately 34 degrees. The lip of the cup is the coolest spot in the model and the middle of the water retained the most heat. The following graph in Figure 9 is the water and single walled cup wall temperature over the course of the 30 minute study. The thermal analysis model appears to be well behaved and utilized the applied boundary conditions appropriately. Figure 9: Plot of the water and single walled glass cup temperature against time Note the spike in thermal heat transfer between the water and cup in the first several minutes of the study. As expected, the top surface of the water loses energy out to the environment while the middle of the water domain remains the hottest spot in the model. The cup temperature peaks around four minutes then steadily drops for the rest of the study. The temperature throughout the wall of the cup is fairly uniform and there is little difference between the inner and outer surfaces of the single wall. The water and glass cup wall steadily drop in temperature in a fairly linear fashion once the initial spike of heat transfer occurs. 13 3.2 COMSOL Heat Transfer in Solids Model – Double Walled Cup The second thermal model created in COMSOL was another time-dependent Heat Transfer in Solids study for the double walled glass cup. The same cup, air, and water geometry used in the single walled study were imported into COMSOL and united. The same relative repair tolerance function in COMSOL was utilized to perform the geometry repair. The repair tolerance was set to 1e-3 millimeters. The material properties for the glass, air, and water were added to their respective domains from the built-in library in COMSOL. See Figure 8 for the location of each material domain. Much like the singled walled glass cup, the thermal model for the double walled glass cup is two-dimensional axisymmetric and features all the same boundary conditions summarized in Figure 3. Zero heat energy is lost to the surrounding environment from the while normal convection heat transfer occurs at the sides and top surface of the water. Convection past a vertical wall were applied to the sides of the of the glass cup model. Convection past a horizontal plate was applied to the exposed surface of the water model. In both natural convection boundary conditions the atmospheric pressure and temperature were set to 1 atm and 293.15 K, respectively. The initial temperature value of the water was set to 373.15 Kelvin. The initial temperature value of the cup was set to 294.26 Kelvin. This would simulate boiled water added to the single walled glass cup at room temperature. The rest of the variables in the thermal equations are satisfied by the material properties and their temperature dependent relationships listed in Table 1. Since the model geometry did not change, the same mesh convergence study performed for the single walled glass cup applies. Based on the convergence study, the mesh size bears no influence on the calculations and a mesh of normal element size would be appropriate for this study. See Table 2 for the results of the convergence study. 14 Like the single walled glass cup study, a stepped time dependent study was performed. The duration was for thirty minutes and with 60 seconds for the maximum step size. Figure 10 is of the results of the thermal model at time = thirty minutes. Figure 10: Double walled cup thermal model at time = 30 minutes After thirty minutes, the water temperature dropped approximately 12 degrees and the cup temperature rose approximately 30 degrees. The lip of the cup is the coolest spot in the model and the middle of the water retained the most heat. The following graph in Figure 11 is the water, air, and double walled cup wall temperature over the course of the 30 minute study. The thermal analysis model appears to be well behaved and utilized the applied boundary conditions appropriately. 15 Figure 11: Plot of the water and double walled glass cup temperature against time Note the spike in thermal heat transfer between the water and cup in the first several minutes of the study. This same behavior was also noted in the single walled cup study. However, due to the air gap there is a significant difference in temperature between points C and D throughout the study in the double walled glass cup versus the single walled glass cup. The cup temperature peaks around ten minutes, significantly later than the single wall glass cup. The water, air, and cup temperatures steadily drop in a fairly linear fashion once the initial spike of heat transfer occurs. Also note that the air trapped between the two walls of glass eventually remains hotter than the top surface of the water. 3.2 Measured Data versus Analytical Model Boiled water was added to the Kiran Tea Glass on hand and the water temperature was measured incrementally as it cooled off. The double walled glass cup was placed on a cork trivet and the room temperature was measured with a digital thermometer [9]. Water was boiled in an electric kettle along with the digital thermometer to bring both the water and the thermometer up to the same starting temperature. The boiled water and thermometer were added to the cup and a stop watch was used to time the 16 measurements. The thermometer was resting on the bottom and side of the cup during the measurement gathering. The measured results data is available in Appendix 1. A graph of the measured temperature versus time can be seen in Figure 12. Water Temperature vs. Time 380,00 370,00 Temperature (K) 360,00 350,00 340,00 Water Temperature 330,00 320,00 310,00 300,00 0 500 1000 1500 2000 Time (s) Figure 12: Measured temperature of boiled water versus time in the Kiran Tea Glass The double walled thermal model was updated to replicate the measured data by changing the ambient and initial temperatures to match the values at the time the measured data was captured. The results are presented in Figure 13. 17 Figure 13: Graph of the temperature of boiled water in the Kiran Tea Glass The behavior between the test study and the thermal model is similar. The spike of energy transfer at the beginning of the studies can be noted in both the measured data and the thermal model. The shape of the curve after the initial spike is also similar between the measured data and the thermal model. However, the heat lost rate and ending temperatures between the measured data and the thermal model differ greatly. Some reasons for the greater heat loss in the measured data than the thermal model may include: the convection coefficients used in the thermal model are lower than reality, significant amounts of energy are lost to the surface the cup rests on even though the cup was resting on an insulating material, the thermometer conducts away extra heat, and the effect of natural convection in the bulk of the water. The biggest driver would be the natural convection coefficients used in the thermal models. 18 4. Conclusions In conclusion, double walled cups are demonstrated to be more effective at keeping hot liquids hot for longer periods of time than single walled cups. The layer of air between two walls of glass allow the double walled cups to perform in a similar fashion to double pane windows where the transfer of heat energy through the cup wall is significantly slowed by the lower thermal conductivity of the air trapped within. The studies themselves are considered successful. The model geometry closely represents the real model from which they were based on, the appropriate boundary conditions for the purpose of this initial study were applied, and the models were not influenced by the mesh size used. The models created are a strong foundation for refined boundary conditions, inputs, and thermal modeling techniques. The water in the double walled cup thermal model exhibited a lower rate of thermal energy loss to the surrounding environment than the single walled cup thermal model. The non-wetted surfaces of the double walled cup gained thermal energy slower than the single walled cup for the duration of the analysis due to the layer of air that significantly slowed the transfer of heat energy from the water to the outside wall of the cup. The measured data verified that the thermal models are well behaved and can be a first step to developing a true representation of what takes places in physical rigs. At this point in time, the thermal models cannot be used to accurately predict the thermal energy loss rate and the temperature of the water at any given time without refinement. Refining of the thermal model would include, simulating the circulation that occurs due to natural convection and converging on the true convection coefficients of the water, air, and glass. The thermal loss through the thermometer and through the bottom of the glass should also be taken into account. 19 5. References 1. R. G. (1999, Feb 22). Starbucks plans to test a paper cup that insulates hands from hot coffee. Wall Street Journal. Retrieved from http://search.proquest.com/docview/398688536?accountid=37764 2. S. K. (1998, Mar 24). These people search for a cup that suits the coffee it holds --the current models can burn fingers, come unglued; mr. sadlier hawks `Insulair'. Wall Street Journal. Retrieved from http://search.proquest.com/docview/398614978?accountid=37764 3. Janninck, W.L. (1969). U.S. Patent No. 3456860. Washington, DC: US Patent and Trademark Office. Retrieved from http://www.google.com/patents?id=qJ9ZAAAAEBAJ&printsec=abstract&zoom=4# v=onepage&q&f=false 4. Singaporean inventors develop double-walled cup. (2009, Sep 18). Indian Patents News. Retrieved from http://search.proquest.com/docview/443239946?accountid=37764 5. 11 oz stoneware coffee mug – white. Retrieved from http://splendids.com/11-ozstoneware-mugs-c-1_130/11-oz-stoneware-coffee-mug-white-p-1013 6. Bodum Bistro 15 oz. Mug & Reviews | Wayfair. Retrieved from http://www.wayfair.com/Bodum-Bistro-15-oz.-Mug-10606-10-BMO1043.html 7. Nave, R. Heat Transfer. Retrieved from http://hyperphysics.phyastr.gsu.edu/hbase/thermo/heatra.html#c1 8. Kiran Tea Glasses at Teavana | Teavana. Retrieved from http://www.teavana.com/tea-products/tea-cups-mugs/glass-tea-cups/p/kiran-teaglasses-8oz 9. Amazon CDN DTC450 Digital Candy Thermometer Retrieved from http://www.amazon.com/gp/product/B00279OPDU 20 6. Appendices 6.1 Appendix 1: Measured temperature data from boiled water in the double walled cup Time (s) 0 60 120 180 240 300 360 420 480 540 600 660 720 780 840 900 960 1020 1080 1140 1200 1260 1320 1380 1440 1500 1560 1620 1680 1740 1800 Temperature Water (F) Temperature 210 372.04 195 363.71 189 360.37 183 357.04 178 354.26 174 352.04 169 349.26 166 347.59 163 345.93 159 343.71 157 342.59 154 340.93 151 339.26 149 338.15 147 337.04 144 335.37 142 334.26 140 333.15 138 332.04 137 331.48 135 330.37 133 329.26 132 328.71 130 327.59 129 327.04 127 325.93 126 325.37 124 324.26 123 323.71 122 323.15 121 322.59 21