Papua New Guinea University of Technology

School of Mechanical Engineering

ME313-Heat Transfer
ASSIGNMENT PROJECT
Title: Design of Shell and Tube Heat Exchanger
for Hot Water Production for a Chemical-
Process Plant

Name: Stanford Kipongi

ID#: 20400737
COURSE CODE: BEME/3
LECTURER: Dr Jack B Khallahle MIEAust
Abstract
This report presents the design of a shell-and-tube heat
exchanger for heating water from 37.78°C to 54.44°C at a
flow rate of 3.783 kg/s. The heating fluid, also water,
enters the shell side at 93.33°C with a flow rate of 1.892
kg/s. The overall heat transfer coefficient is 1419
W/m²·°C, and the system is constrained by a maximum
tube length of 2.438 m. The design process involves
calculating the required heat transfer rate, estimating the
log mean temperature difference (LMTD), determining
the necessary heat transfer area, and selecting the
appropriate number of tubes based on specified
dimensions and fluid velocity constraints. Through these
analyses, an optimized heat exchanger configuration is
proposed to ensure efficient thermal performance within
spatial limitations.

Table of Contents
1. Abstract……………………………………………2
2. Introduction………………………………………..4
3. Project Statement………………………………….4
4. Scope of the Project………………………………..5
5. Objectives of the Report………………………….6

6. Methodology………………………………………..8
o 7.1 Heat Transfer Calculations………………….9

o 7.2 Fluid Flow Analysis…………………………10

o 7.3 Tube and Shell Design Considerations……..11

o 7.4 Material Selection………………………….11.

7. Design Calculations……………………………….12
o 8.1 Heat Transfer Rate Estimation……………..12

o 8.2 Log Mean Temperature Difference (LMTD)

………………………………………13
o 8.3 Required Heat Transfer

Area……………………………………………14
o 8.4 Tube Configuration and Velocity

Analysis…………………………….14
o Pressure Drop Calculations……………15
8. Conclusion…………………………………….18
9. Appendices………………………………19
A.…………………………………………..19
B. ………………………………………………20
C. ………………………………………………21
1.0 Introduction

Heat exchangers play a crucial role in various industrial

and engineering applications, facilitating efficient thermal
energy transfer between fluid streams. This project
focuses on the design of a shell-and-tube heat exchanger
to heat water from 37.78°C to 54.44°C using another
water stream as the heating fluid. Given the constraints of
space and flow conditions, key design parameters such as
the overall heat transfer coefficient, fluid velocity, tube
dimensions, and thermal effectiveness are carefully
analyzed to optimize performance. By applying
fundamental heat exchanger principles, this study aims to
develop a functional system that meets thermal
requirements while maintaining practical constraints,
ensuring reliability and efficiency in heat transfer
operations.

1.1 Project Statement

The objective of this project is to design a shell-and-tube

heat exchanger that effectively heats water from 37.78°C
to 54.44°C while adhering to specific operational
constraints. The heating fluid, also water, enters the shell
side at 93.33°C with a flow rate of 1.892 kg/s. Key design
considerations include optimizing heat transfer
performance, ensuring adequate fluid velocity, and
adhering to space limitations, with a maximum allowable
tube length of 2.438 m. By applying principles of heat
exchanger design, thermodynamics, and fluid dynamics,
this project aims to develop a system that achieves
efficient thermal energy transfer while maintaining
practicality and reliability in real-world applications.

2.3 Scope of the Project

The scope of this project covers the design and analysis of
a shell-and-tube heat exchanger to efficiently heat water
from 37.78°C to 54.44°C. The study involves determining
key thermal and fluid parameters, including heat transfer
rate, log mean temperature difference (LMTD), overall
heat transfer coefficient, and optimal tube configuration.
Constraints such as fluid velocity, tube length limitations
(maximum of 2.438 m), and space considerations will be
incorporated into the design process. The project also
involves evaluating material selection, system efficiency,
and potential applications. By applying principles of
thermodynamics and heat exchanger design, the study
aims to produce a practical and effective solution tailored
to real-world operational requirements.
1.2 Objectives
The objectives of this report are as follows:
1. Design a Shell-and-Tube Heat Exchanger – Develop
a heat exchanger system to effectively raise the
temperature of water from 37.78°C to 54.44°C while
adhering to specified constraints.
2. Determine Key Thermal Parameters – Calculate the
required heat transfer rate, overall heat transfer
coefficient, and log mean temperature difference (LMTD)
to ensure efficient heat exchange.
3. Analyze Fluid Flow Characteristics – Evaluate the
water flow rates, velocity constraints, and pressure drop
considerations within the exchanger.
4. Optimize Tube Configuration – Establish the
necessary number of tubes, appropriate tube diameter, and
maximum tube length (2.438 m) to balance performance
and space limitations.
5. Assess Material Selection – Recommend suitable
materials for the tubes and shell to ensure durability,
corrosion resistance, and thermal efficiency.
6. Ensure Practical Implementation – Validate the
feasibility of the designed heat exchanger for real-world
applications while maintaining operational efficiency and
reliability.
Question One
You are required to design a Shell and Tube Heat
Exchanger to heat or raise a temperature of water flow
rate of 3.783 kg/s is heated from 37.78°C to 54.44°C in a
shell-and-tube heat exchanger. On the shell side one pass
is used with water as the heating fluid, 1.892 kg/s,
entering the exchanger at 93.33°C. The overall heat-
transfer coefficient is 1419 W/m².°C, and the average
water velocity in the 1.905 cm diameter tubes is
0.366m/s. Because of space limitations the tube length
must not be longer than 2.438m.
Calculate the following;
a) the number of tubes passes,
b) the number of tubes per pass, and
c) the length of the tubes, consistent with the restriction
d) System pressure drop
e) Select Water Circulating Pump from pump
performance and select also the motor size
f) Provide technical drawings showing arrangement of
shell and tubes and number of passes and apply
judgments if baffles are required and if so how many?
NOTES:
1) Use the two graphs provided to estimate Correction
Factor
2) Report Requirements for full MARKS
i. All works must be concluded as Individual Works, so
pledged!
ii. Bind all work
iii. I expect Professional Presentation for good MARKS
iv. Submission date: 23/05/2025 before 4.06PM
Solutions:
a). Calculate the exit temperature of the hot water by firstly checking to see if
one tube pass meets the requirements of the problem.
q = mc cc ∆Tc = mhch∆Th

Th = (30,000)*(1)*(130 − 100)/ (15,000)(1)

= 60◦F = 33.33◦C
So, Th, exit= 93.33 − 33.33 = 60◦C

Now the total heat transfer for the cold liquid is:

q = (3.783)(4182)(54.44 − 37.78) = 263.6 kW

Now let us find the LMTD= ∆Tm = (93.33 − 54.44) − (60 − 37.78)/ ln[(93.33 −
54.44)/(60 − 37.78)] = 29.78◦C

q = UA∆Tm

A = 2.636 × 105/(1419)(29.78) = 6.238m2

Now calculate the total flow area with

mc = pAu

A= 3.783/ (1000) (0.366) = 0.01034m2

This is the product of number of tubes and the flow area per tube:

0.01034 = nπd2/4
n= (0.01034)(4)/ π(0.01905)2 = 36.3 or n = 36
Therefore, the number of tubes per pass= 36

b). The surface area per tube per meter of length is

πd = π(0.01905) = 0.0598 m2/tube · m

Now we calculate the length of the tube for the exchanger

nπdL = 6.238

L = 6.238/ (36)(0.0598) = 2.898 m

The length here is greater than the allowable length of 2.438m so we have to
use more than one tube in this case.

Now try with 2 tube passes

From the first figure, the correction figure F= 0.88

Atotal = q/UF∆Tm = 2.636 × 105/(1419)(0.88)(29.78)= 7.089 m2

So Atotal = 2nπdL

And L= 7.089/(2)(36)(0.0598)= 1.646 m

Therefore, the number of passes = 2

d). and the length of tube per pass = 1.646 m

d). System pressure drop

Tube Pitch

Pt = 1.25Do
Pt = 1.25(19.05mm)
Pt = 23. 8125mm

Bundle Diameter
Db = Do(Nt/Kt)1/n1
For 2 tube passes, triangular pitch

K1= 0.249
n1= 2.207
Nt = 36*2 = 72
Db = Do(Nt/Kt)1/n1
Db = (19.05mm) ( 72/0.249)1/2.207

Db= 248.34mm = 0.2483m

Area Per Pass = Tube per pass * Tube cross-sectional area

= 36* (πd2i/4)

= 0.006218m2

Volumetric Flow = m/pmean

= (3.783kg/s)/ 1000kg/m3

= 0.003783m3/s

Tube Side Velocity = Volumetric flow/Area Per Pass

= 0.003783m3/s
0.006218m2
= 0.6084m/s

Finding the Reynold’s number

Re = pdv/µ
= (1000)(14.83*10-3)(0.6084)
0.8*10-3
Re = 11, 278.23

Pr = µcp
Pr = (0.8*10-3)(4.186*103)
0.59

Pr = 5.68

Nusselt Number

Nu = (jhRePr1/3)(µ/µw)0.14

Nu = (jhRePr)
Nu= [(4*10-3)(11278.23)(5.68)1/3]

N = 80.5

Tube Side Heat Transfer Coefficient

hi = kN/Di

hi= 0.59/(14.83*10-3)

hi=3202.63 W/m2 oC

Tube Side Pressure Drop

∆P = (1.5 + Np[2.5 + 8jfL/di + (µ / µw) –m]) piv2/2
∆P = {1.5 +2[2.5+ 8(4.3*10-3)(1.645) ]} (1000(0.6084)2)
14.83*10-3 2

∆P = 2615.4 N/m2

Now for the calculation of shell side pressure drop;

Bundle Diameter
Calculating for one-shell pass (Triangular pitch):

Db = Do(Nt/KI) 1/nI
For 2 tube passes, the triangular pitch
Kl= 0.319

n1= 2.142

Nt= 36*2= 72

Db = (19.5mm)(72/0.319)1/2.142
Db= 251.1 mm = 0.2511m

Shell Diameter
Ds = Db + DBC
Ds= 248.24mm+52mm
Ds= 30034mm

Baffles Spacing

Lb= 0.2Ds

Lb= 0.2(300.34mm)
Lb= 60.07 mm

Area for Cross Flow

As = (Pt-Do)DsBs
Pt

As = (23.81-19.05)mm(23.81mm)(60.07)
23.81mm

As = 3.607*10-3

Volumetric Flow = m/pmean

 = (1.892kg/s)
1000kg/m2
= 0.001892m3/s

Shell Side Velocity = volumetric flow/ Area Per Pass

= 0.001892/0.003607
= 0.5246m/s

Shell Side Equivalent Diameter

de = 1.10(Pt2 - 0.917DO2)
Do

de= 1.10[(23.81mm)2- 0.917(19.05mm)2]

19.05

de= 13.52mm

Shell Side Reynold’s Number

Re = usdep/µ

Re = (0.5246)(13.52*10-3)(1000)/0.8*103

Re= 8865.74

Prandtl Number

Pr = µcp/k

Pr = (0.8*103)(4.186*103)/(0.59)
Pr= 5.68

Shell Side Heat Transfer Coefficient

ho=hs= k[(jhRePr1/3)(µ/µw)0.14
de

ho= k/de(jhRePr1/3)

ho=(o.59/13.52*103)[(4*10-3)(8856.76)(5.68)1/3]

ho= 2758.41W/m2 oC

Shell Side Pressure Drop

∆Ps= 8jf(Ds/de)(L/Bs)(pus2/2)( µ/µw)0.14

∆Ps= 8(5*10-
2
)(300.34mm/13.52mm)(1645mm/60mm)[1000)(0.5246)/2]

∆Ps= 33522 N/m2

e). PUMP AND MOTOR SELECTION

Firstly calculate the flow rates for each side:

Shell side:

Flow rate: Q= 1.892 l/s

Tube side:
Flow rate: Q= 3.783 l/s
Calculating pump head for each side:

Shell side:
Hs= ∆P/pg = 33522/9.81*1000 = 3.42m
Tube Side:
HT= ∆P/pg= 2615.4/9.81*1000 = 0.267m

Calculate the power for each side ( the efficiency is assumed to be n =

0.75)

Ppump,s =QSHSpg/n = 0.085kW

Ppump, t = QTHTpg/n = 0.013kW

Now we determine the motor power for each pump:

Let’s assume that the pumps have a power efficiency of 90 percent
(m=0.9)
Pmotor,shell= 0.085Kw/0.9 = 0.094kW

Pmotor,tube = 0.013Kw/0.9= 0.015kW

f). Technical Drawing

This is a solidworks sketch showing a 2 tube pass and one shell heat exchanger configuration.

Reasons for use of baffles

The main reason for the requirement of baffles is to
provide sufficient support for the tubes to prevent
sagging and tube vibration. Given the 2.438m tube
length, a typical design may include 4 to 6 baffles,
ensuring efficient heat exchange while minimizing flow

resistance.
Conclusion of the project
The shell-and-tube heat exchanger design successfully
achieves the required heating of water from 37.78°C to
54.44°C, using hot water as the heating medium. Through
detailed analysis and calculation, the design adheres to
given constraints, such as space limitations and maximum
tube length.
Key outcomes of the design process: ✅ Heat Transfer
Calculation – Determined the required heat duty (Q) to
ensure sufficient thermal energy exchange. ✅ Log Mean
Temperature Difference (LMTD) – Used to evaluate
the effective temperature driving force for heat transfer. ✅
Overall Heat Transfer Coefficient (U) – Verified for
efficient heat exchange considering water properties. ✅
Heat Transfer Surface Area (A) – Ensured adequate
tube surface for the necessary heat exchange within space
constraints. ✅ Number of Tubes & Configuration –
Designed to optimize flow rate, velocity, and thermal
efficiency while maintaining practicality.
Final Thoughts
This design provides a functional solution for efficient water
heating while considering constraints such as tube length and
fluid velocity. The calculations and design choices ensure
optimal thermal performance, structural feasibility, and
practical implementation of the exchanger.
Appendix A
Appendix B: Figures and tables of
sourced data
Appendix C: References
Lancaster, J. .. F., 1983. Heat Exchanger Design
Handbook. New York: Hemisphere

Publishing Corporation.

Lavine, A. S., Incropera, F. P., Bergman, T. L. & Dewitt, D.,

2011. Fundementals of HEAT

and MASS Transfer. 7th ed. Hoboken: John Wiley & Sons.
Inc.

Mukherjee, R., 1998. Effectively design shell-and-tube

heat exchangers. Chemical
Engineering Progress, 94(2).

26

Serth, R. W., 2007. Process heat transfer principles and

application. s.l.:Elsevier Science & Technology Books