FACULTY OF ENGINEERING TECHNOLOGY AND BUILT

ENVIRONMENT (FETBE)

BEP3033 HEAT TRANSFER

Group 4 Assignment

Percentage of
Student Name Student ID Contribution to section contribution to Signature
report (%)
Design calculations &
Nowshad* 1001955556 discussion on the heat 25
exchanger design
Description of the design of
Gwendelyn
1001957287 a shell and tube heat 25
Ho Hooi Sze
exchanger, brief discussion
Design calculations &
Yan Swee
1002057448 discussion on the heat 25
Cheiin
exchanger design
Introduce the role of heat
Lorna exchangers in chemical
Ahlaami Binti 1001851777 industries, types of heat 25
Ramzan exchangers available &
discussion.

Lecturer: Assoc. Prof. Ir. Dr. Lee Kiat Moon

JAN – APRIL 2023

Table of Contents

1.0 Introduction ........................................................................................................................ 3

2.0 Design Assumption............................................................................................................. 7

3.0 Design Calculation ............................................................................................................. 9

4.0 Discussion.......................................................................................................................... 18

5.0 References ......................................................................................................................... 23

1.0 Introduction

Heat exchangers are devices that facilitate the exchange of heat between two fluids that are at
different temperatures while keeping them from mixing with each other. Heat exchangers are
commonly used in practice in a wide range of applications, from heating and air-conditioning
systems in a household, to chemical processing and power production in large plants. Heat
exchangers differ from mixing chambers in that they do not allow the two fluids involved to
mix.

1. Types of heat exchangers

Different heat transfer applications necessitate different kinds of hardware and heat transfer
equipment configurations. The effort to match heat transfer hardware to heat transfer
requirements within specified constraints has led in a wide range of innovative heat exchanger
designs.

Figure 1: Illustrations of parallel flow and counter flow in double pipes (Cengel et al, 2011)

The double-pipe heat exchanger is the most basic form of heat exchanger, consisting of two
concentric pipes of varying diameters, as shown in Figure 1. In a two-pipe heat exchanger, one
fluid travels through the smaller pipe, while the other flows through the annular space between
the two pipes. In a double-pipe heat exchanger, two kinds of flow arrangements are possible:
parallel flow and serial flow. In parallel flow, both hot and cold fluids enter the heat exchanger
at the same end and move in the same direction. In contrast, in counterflow, hot and cold fluids
enter the heat exchanger from opposite ends and flow in opposite directions.
Figure 2: Illustrations of fluids unmixed (a) and fluid mixed, one fluid unmixed (b) (Çengel et
al, 2011)

Typically, in compact heat exchangers, the two fluids move perpendicular to one another,
which is known as cross-flow. Depending on the flow configuration, cross-flow is further
categorized as unmixed or mixed flow. The direction of flow of fluids in a heat exchanger can
be either mixed or unmixed. When the fluid flows through the interfin spacing in a particular
direction, without any freedom to move in the transverse direction (parallel to the tubes), it is
considered unmixed. This happens in cross-flow heat exchangers where plate fins force the
fluid to follow a specific path. On the other hand, when the fluid can move in the transverse
direction, it is considered mixed. This occurs in other types of heat exchangers, where the fluid
has the freedom to move in multiple directions.

The presence of mixing in the fluid can significantly impact the heat transfer characteristics of
the heat exchanger. In unmixed flows, the fluid moves in a single direction, which means the
heat transfer occurs primarily through conduction. This allows for more efficient heat transfer
as the heat is easily transferred in one direction. However, in mixed flows, the fluid can move
in multiple directions, which can lead to turbulence and reduce the overall efficiency of heat
transfer. This is why in car radiators, where both fluids are unmixed, efficient heat transfer is
achieved through a single direction of flow.
Figure 3: Illustration of shell and tube heat exchanger (Çengel et al, 2011)

One of the most common types of heat exchangers used in industrial applications is the shell-
and-tube heat exchanger. It consists of numerous tubes arranged in a shell with their axes
parallel to the shell. One fluid flow inside the tubes while the other flows outside the tubes
through the shell, allowing for heat transfer. Baffles are placed in the shell to enhance heat
transfer and maintain uniform spacing between the tubes.(Bichkar et al., 2018)

Although shell-and-tube heat exchangers are commonly used, they are not suitable for use in
automotive and aircraft applications due to their large size and weight. The tubes in a shell-
and-tube heat exchanger open to flow areas called headers at both ends of the shell, where the
fluid accumulates before and after entering the tubes.

Figure 4: Illustration of called one-shell-pass and two-tube-passes heat exchangers (a) and a
two-shell-passes and four-tube-passes heat exchanger (b) (Çengel et al, 2011)

Shell-and-tube heat exchangers can be classified based on the number of shell and tube passes
involved. Heat exchangers in which all the tubes make one U-turn in the shell are called one-
shell-pass and two-tube-passes heat exchangers. Similarly, a heat exchanger that involves two
passes in the shell and four passes in the tubes is called a two-shell-passes and four-tube-passes
heat exchanger. This classification helps in determining the heat transfer efficiency of the heat
exchanger and selecting the appropriate heat exchanger for a given application.

Figure 5: Illustration of plate heat exchanger (Ryan et al, 2021)

A plate heat exchanger is a type of heat exchanger that consists of a series of thin, flat plates
with corrugated ridges that form flow passages between them. The hot and cold fluids flow
through alternate passages, allowing for efficient heat transfer. The plates are typically made
of stainless steel or titanium and are held together by gaskets and frame plates.

Plate heat exchangers offer several advantages over other types of heat exchangers. Their
compact design and high surface area-to-volume ratio make them well-suited for applications
where space is limited. Additionally, their modular design allows for easy expansion or
modification of the heat exchanger. They are also more efficient than shell-and-tube heat
exchangers due to their counter-current flow configuration, which allows for greater
temperature differences between the hot and cold fluids.

Plate heat exchangers are commonly used in liquid-to-liquid heat exchange applications, such
as in the food and beverage, chemical, and pharmaceutical industries. They are also used in
HVAC systems, refrigeration systems, and in waste heat recovery applications. However, plate
heat exchangers are not suitable for high-pressure applications or applications where the hot
and cold fluids have significantly different viscosities.

To maintain efficient heat transfer and prevent fouling or scaling of the plates, it is important
to properly clean and maintain plate heat exchangers. This can involve periodic cleaning of the
plates or installation of automatic cleaning systems.
2.0 Design Assumption

Design constraints:

1. Due to space limitation, tube length must not exceed 1m.

2. Due to pump capacity, maximum amount of stream not exceed 1.5 kg/s.
3. No phase change in fluids.

Figure 6: Cross Flow Heat Exchanger

Parameters/material used for Heat Exchanger: -

i. Flow direction of heat exchanger

There are three different types of fluid flow existed in heat exchanger which are the
counter flow, parallel flow, and counter flow. Parallel flow is when both the tube side
and the shell side fluid flow in the same direction. It is when the temperature difference
between the hot and cold fluid is relatively small. Counter flow is when two fluid flow
in opposite directions. Whereas, cross flow is when one fluid flow perpendicular to the
second fluid, that is one fluid flows through the tubes and the second fluid passes
through the tube at 90° angle. It is typically used when there is a large temperature
difference between the hot and cold fluids. When the hot and cold fluids flow
perpendicular to each other, it allows efficient heat transfer across the surface area of
the heat exchanger. Therefore, cross flow direction was used in as it is able to show
the major difference in temperature and it provide higher heat transfer rate when there
is an increase in the surface area of heat transfer.
ii. Copper material
Copper is used for heat exchanger due to its high thermal conductivity allows heat to
pass through it quickly as well as it being inexpensive compared to other material such
as stainless steel. Because of its great thermal conductivity and corrosion resistance,
copper is a common material option for heat exchangers. Because of these qualities, it
is an excellent choice for applications involving heat transfer from one fluid to another,
such as air conditioning systems, refrigeration units, and industrial process equipment.
It is also important to note that the usage of copper can resist a broad variety of
temperatures, which is why it is highly recommended. It's also a fantastic choice for
heat exchangers that need to be cleaned or maintained frequently because it's easy to
clean and doesn't corrode quickly. Besides that, copper is also stable. It is able to
withstand cold, heat, pressure, corrosion, and fire resistance. The long-term
performance and dependability of copper, on the other hand, may justify the extra cost.
Overall, due to its high thermal and corrosion qualities, copper is a good material option
for heat exchangers and is widely utilized in a range of sectors. Hence, copper material
was used in shell-and-tube heat exchanger.
iii. Type of flow

Shell and tube heat exchangers are designed to operate under turbulent flow
conditions. Turbulent flow is preferred because it enhances heat transfer by promoting
mixing of the fluid streams, which in turn reduces the boundary layer thickness and
increases the convective heat transfer coefficient. Turbulent flow also helps to prevent
fouling and corrosion by promoting the removal of stagnant fluid and debris from the
heat transfer surfaces.

In contrast, laminar flow, which occurs at lower velocities, creates a thicker boundary
layer that reduces the convective heat transfer coefficient and limits mixing of the
fluid streams. This results in lower heat transfer rates and increased susceptibility to
fouling and corrosion.

Therefore, in order to maximize the efficiency and effectiveness of a shell and tube
heat exchanger, it is designed to operate under turbulent flow conditions. This is
achieved by optimizing the flow velocity, geometry, and arrangement of the tubes and
baffles within the shell to promote fluid mixing and reduce boundary layer thickness.

Assumptions:

a. It is in a steady operation condition.

b. The heat exchanger is well insulated; hence, the heat loss to the surrounding is
negligible.
c. Kinetic and potential energies of the fluids are negligible.
d. In view of the tube in thin-walled and highly conductive, the thermal resistance of the
inner tube is negligible.
e. The heat transfer coefficients are constant and uniform.

3.0 Design Calculation

The following steps are involved in designing a shell-and-tube heat exchanger using the
LMTD method:

Step 1: Determination of heat duty

The amount of heat transferred from steam to water is referred to as the heat duty. The
following equation can be used to calculate it:

𝑄𝑄 = (𝑚𝑚𝑤𝑤𝑤𝑤𝑤𝑤𝑤𝑤𝑤𝑤 )(𝐶𝐶𝑝𝑝𝑤𝑤𝑤𝑤𝑤𝑤𝑤𝑤𝑤𝑤 )(𝑇𝑇𝑜𝑜𝑜𝑜𝑜𝑜 − 𝑇𝑇𝑖𝑖𝑖𝑖 )

where:

𝑚𝑚𝑤𝑤𝑤𝑤𝑤𝑤𝑤𝑤𝑤𝑤 = mass flow rate of water

𝐶𝐶𝑝𝑝𝑤𝑤𝑤𝑤𝑤𝑤𝑤𝑤𝑤𝑤 = specific heat capacity of water

𝑇𝑇𝑜𝑜𝑜𝑜𝑜𝑜 = desired outlet temperature of water

𝑇𝑇𝑖𝑖𝑖𝑖 = inlet temperature of water

Given:

𝑇𝑇𝑐𝑐 𝑖𝑖𝑛𝑛 = 25°𝐶𝐶 𝑇𝑇ℎ 𝑖𝑖𝑖𝑖 = 335°𝐶𝐶

𝑚𝑚
𝑇𝑇𝑐𝑐 𝑜𝑜𝑜𝑜𝑜𝑜 = 89°𝐶𝐶 𝜐𝜐 = 5
𝑠𝑠

𝑘𝑘𝑘𝑘
Mass flow rate of steam is assumed which is 1.50588 𝑠𝑠
.

𝑘𝑘𝑘𝑘
Assuming that the mass flow rate of water is 4 𝑠𝑠
. Hence, the heat duty is calculated as
below:
𝑄𝑄 = (𝑚𝑚𝑤𝑤𝑤𝑤𝑤𝑤𝑤𝑤𝑤𝑤 )(𝐶𝐶𝑝𝑝𝑤𝑤𝑤𝑤𝑤𝑤𝑤𝑤𝑤𝑤 )(𝑇𝑇𝑐𝑐 𝑜𝑜𝑜𝑜𝑜𝑜 − 𝑇𝑇𝑐𝑐 𝑖𝑖𝑖𝑖 )
𝑘𝑘𝑘𝑘 𝐽𝐽
= �4 � �4184 � (89°𝐶𝐶 − 25°𝐶𝐶)
𝑠𝑠 𝑘𝑘𝑘𝑘.  °𝐶𝐶
= 1071.104 𝑘𝑘𝑘𝑘 

From of conservation of heat:

The heat loss from steam will be the same as the heat gained by the water which is

due to the conservation of energy.

𝑄𝑄 = 𝑚𝑚ℎ 𝐶𝐶𝑝𝑝 ℎ (Δ𝑇𝑇) = 𝑚𝑚𝑐𝑐 𝐶𝐶𝑝𝑝 𝑐𝑐 (Δ𝑡𝑡)

𝑘𝑘𝑘𝑘 𝑘𝑘𝑘𝑘
�1.50588  � (Δ𝑇𝑇) = �4  � (89 𝑜𝑜 𝐶𝐶  −  25 𝑜𝑜 𝐶𝐶)
𝑠𝑠 𝑠𝑠
Δ𝑇𝑇 = 170°𝐶𝐶
∆𝑇𝑇 = 𝑇𝑇ℎ,𝑖𝑖𝑖𝑖 − 𝑇𝑇ℎ,𝑜𝑜𝑜𝑜𝑜𝑜
𝑇𝑇ℎ,𝑜𝑜𝑜𝑜𝑜𝑜 = 𝑇𝑇2
𝑇𝑇ℎ,𝑜𝑜𝑜𝑜𝑜𝑜 = 335°𝐶𝐶 − 170°𝐶𝐶
𝑇𝑇ℎ,𝑜𝑜𝑜𝑜𝑜𝑜 = 165 𝑜𝑜 𝐶𝐶

Step 2: Determination of mean temperature difference (𝚫𝚫𝑻𝑻𝒍𝒍𝒍𝒍 )

Δ𝑇𝑇1 − Δ𝑇𝑇2
Δ𝑇𝑇𝑙𝑙𝑙𝑙 =
Δ𝑇𝑇
ln �Δ𝑇𝑇1 �
2
Δ𝑇𝑇1 = 𝑇𝑇ℎ,𝑖𝑖𝑖𝑖 − 𝑇𝑇𝑐𝑐,𝑜𝑜𝑜𝑜𝑜𝑜 
= 335°𝐶𝐶 − 89°𝐶𝐶 
= 246°𝐶𝐶
Δ𝑇𝑇2   =  𝑇𝑇ℎ,𝑜𝑜𝑜𝑜𝑜𝑜 − 𝑇𝑇𝑐𝑐,𝑖𝑖𝑖𝑖  
= 165  −  25 
=  140 𝑜𝑜 𝐶𝐶
246 𝑜𝑜 𝐶𝐶  −  140 𝑜𝑜 𝐶𝐶
Δ𝑇𝑇𝑙𝑙𝑙𝑙 =  
246
ln �
140�
𝑜𝑜
Δ𝑇𝑇𝑙𝑙𝑙𝑙 =  188.05  𝐶𝐶

Assumed the pipe is a 2-in schedule 40

𝐼𝐼𝐼𝐼 = 0.0525𝑚𝑚 𝑂𝑂𝑂𝑂 = 0.06033𝑚𝑚

Step 3: Determination of Overall Heat Transfer Coefficient:

1
𝑈𝑈𝑜𝑜 𝐴𝐴𝑜𝑜 =   1 Δ𝑥𝑥 1 (Assuming Ao = Ai =Ao =Alm)
+ +
ℎ𝑖𝑖 𝐴𝐴𝑖𝑖 𝑘𝑘𝐴𝐴𝑙𝑙𝑙𝑙 ℎ𝑜𝑜 𝐴𝐴0

For Copper pipe thermal conductivity, 𝑘𝑘𝐶𝐶𝐶𝐶 = 398 𝑊𝑊⁄𝑚𝑚 ∙ °𝐶𝐶,

Properties of water in tube at mean bulk fluid temperature, T(avg) = 57 °C, Pressure = 1.013
bar, assuming velocity of water is 20 m/s

25 + 89
𝑇𝑇𝑎𝑎𝑎𝑎𝑎𝑎 = °𝐶𝐶
2
= 57°𝐶𝐶

From the saturated water table (Evans, 2017),

𝜌𝜌 − 985.71 57 − 55 𝑘𝑘 − 0.649 57 − 55
= =
983.21 − 985.71 60 − 55 0.654 − 0.649 60 − 55
𝜌𝜌 − 985.71 𝑘𝑘 − 0.649
= 0.4 = 0.4
−2.5 0.005
𝜌𝜌 = 984.71 𝑘𝑘𝑘𝑘⁄𝑚𝑚3 𝑘𝑘 = 0.651 𝑊𝑊 ⁄𝑚𝑚 ∙ °𝐶𝐶

𝜇𝜇 − 0.000504 57 − 55 𝑃𝑃𝑃𝑃 − 3.25 57 − 55

= =
0.000466 − 0.000504 60 − 55 2.98 − 3.25 60 − 55
𝜇𝜇 − 0.000504 𝑃𝑃𝑃𝑃 − 3.25
= 0.4 = 0.4
−0.000038 −0.27
𝜇𝜇 = 0.0004888𝑃𝑃𝑃𝑃 ∙ 𝑠𝑠 𝑃𝑃𝑃𝑃 = 3.142

𝑘𝑘𝑘𝑘 𝑘𝑘𝑘𝑘 𝑊𝑊
𝜌𝜌 = 984.71 
𝑚𝑚3
, 𝜇𝜇 = 0.0004888 
𝑚𝑚∙𝑠𝑠
, 𝑘𝑘 = 0.651 
𝑚𝑚∙°𝐶𝐶
, 𝑃𝑃𝑃𝑃 = 3.142;

𝜌𝜌𝜌𝜌𝜌𝜌
𝑅𝑅𝑅𝑅𝑤𝑤𝑤𝑤𝑤𝑤𝑤𝑤𝑤𝑤 =
𝜇𝜇
(984.71)(20)(0.0525)
=
0.0004888
= 2115273.12

For turbulent flow through tube:

𝑁𝑁𝑁𝑁 =  0.023𝑅𝑅𝑒𝑒 0.8 (𝑃𝑃𝑃𝑃)0.3

= 0.023(2115273.12)0.8 (3.142)0.3
= 3725.5
𝑘𝑘
ℎ𝑖𝑖   =  𝑁𝑁𝑁𝑁 � �
𝑑𝑑
0.651
= 3725.5 � �
0.0525
𝑊𝑊
= 46196.2 
𝑚𝑚2∙ °𝐶𝐶

Properties of saturated steam in shell at mean bulk fluid temperature, T(avg) = 250 °C,
Pressure is 39.737 bar, Velocity is 5 m/s, Tube outer diameter is 0.06033m;

335 + 165
𝑇𝑇𝑎𝑎𝑎𝑎𝑎𝑎 = °𝐶𝐶
2
= 250°𝐶𝐶

According to (STEAM TABLES, n.d.), from table 1,

Density, 𝜌𝜌:

𝑘𝑘𝑘𝑘
𝜌𝜌 =  19.956 
𝑚𝑚3

According to (STEAM TABLES, n.d.), from table 5,

Dynamic viscosity, 𝜇𝜇:

𝜇𝜇 − (17.83 × 10−6 ) 39.737 − 25

−6 −6
=
(106.1 × 10 ) − (17.83 × 10 ) 50 − 25
𝜇𝜇 − (17.83 × 10−6 )
= 0.58948
8.827 × 10−5
𝜇𝜇 = 0.00006986 𝑘𝑘𝑘𝑘⁄𝑚𝑚 ∙ 𝑠𝑠 (𝑃𝑃𝑃𝑃 ∙ 𝑠𝑠)

According to (STEAM TABLES, n.d.), from table 6,

Thermal conductivity, k:

𝑘𝑘 − 0.04516 39.737 − 25
=
0.6227 − 0.04516 50 − 25
𝑘𝑘 − 0.04516
= 0.58948
0.57754
𝑘𝑘 = 0.38561 𝑊𝑊 ⁄𝑚𝑚 ∙ °𝐶𝐶

According to (STEAM TABLES, n.d.), from table 7,

Prandtl Number, Pr:

𝑃𝑃𝑃𝑃 − 1.096 39.737 − 25

=
0.825 − 1.096 50 − 25
𝑃𝑃𝑃𝑃 − 1.096
= 0.58948
−0.271
𝑃𝑃𝑃𝑃 = 0.9363
𝑃𝑃𝑃𝑃 = 0.9363 (Momentum transfer is high but heat diffusivity is lower)

𝜌𝜌𝜌𝜌𝜌𝜌
𝑅𝑅𝑅𝑅𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠 =
𝜇𝜇
(19.956)(5)(0.06033)
=
0.00006986
= 86168.44
1
For cross flow over cylindrical tube: 𝑁𝑁𝑁𝑁  =  𝐶𝐶 𝑁𝑁𝑅𝑅𝑅𝑅
𝑚𝑚
 𝑁𝑁𝑃𝑃𝑃𝑃
3

1
𝑁𝑁𝑁𝑁  =  0.027𝑅𝑅𝑒𝑒 0.805 𝑃𝑃𝑟𝑟 3  
1
= 0.027(86168.44)0.805 (0.9363)3
= 248.19
𝑘𝑘
ℎ𝑜𝑜   =  𝑁𝑁𝑁𝑁 � �
𝑑𝑑
0.38561
=  248.19 � �
0.06033
𝑊𝑊
= 1586.35 2
𝑚𝑚 ∙ °𝐶𝐶

Assuming Ao = Ai =Ao =Alm for calculating overall heat transfer coefficient:

1
𝑈𝑈  =  
1 Δ𝑥𝑥 1
+ +
ℎ𝑖𝑖 𝑘𝑘 ℎ𝑜𝑜
1
=
1 (0.06033 − 0.0525) 1
46196.2 + 398 +
1586.35
𝑊𝑊
= 1488.76  2 𝑜𝑜
𝑚𝑚 .   𝐶𝐶
𝐵𝐵𝐵𝐵𝐵𝐵 𝑊𝑊
Assumed the overall heat transfer coefficient, (U) is �262.19  ℎ𝑟𝑟.𝑓𝑓𝑡𝑡 2. 𝑜𝑜𝐹𝐹� or �1488.76  𝑚𝑚2. 𝑜𝑜𝐶𝐶�

𝑡𝑡2 − 𝑡𝑡1 𝑇𝑇1 − 𝑇𝑇2

𝑃𝑃 = 𝑅𝑅 =
𝑇𝑇1 −  𝑡𝑡1 𝑡𝑡2 − 𝑡𝑡1
89 − 25 335  −  165
= =
335 − 25 89  −  25
= 0.206 = 2.656
Figure 7: Correction factor plot for exchanger with one shell pass and two, four, or any
multiple of tube passes.

𝑄𝑄 = 𝑈𝑈𝑈𝑈𝑈𝑈Δ𝑇𝑇𝑙𝑙𝑙𝑙 (Where F is Correction factor for 2 pass)

From figure 7, the correction factor, 𝐹𝐹 = 0.96

𝑄𝑄
𝐴𝐴 =
𝑈𝑈𝑈𝑈Δ𝑇𝑇𝑙𝑙𝑙𝑙
1071.104  ×  103  𝑊𝑊
=
𝑊𝑊
�1488.76  2 � (0.96)(188.05°𝐶𝐶)
𝑚𝑚 . °𝐶𝐶
= 3.985 𝑚𝑚2

∴  𝐻𝐻𝐻𝐻𝐻𝐻𝐻𝐻 𝑡𝑡𝑡𝑡𝑡𝑡𝑡𝑡𝑡𝑡𝑡𝑡𝑡𝑡𝑡𝑡 𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎,  𝐴𝐴 =  3.985 𝑚𝑚2

Amount of water can be heated to desired temperature, 𝑚𝑚̇

Mass flow rate of water, 𝑚𝑚̇ = 4 kg/s where 4 kg of water comes in contact with 3.985 m2 area
in 1 second and gain heat energy and rises in temperature from 25oC to 89oC.

Cross-sectional area to sustain the velocity and mass flow rate of water is given as:

Where Acs is the cross-sectional area,

 𝑚𝑚̇ 𝑐𝑐   = 𝜌𝜌𝑐𝑐  𝑣𝑣𝑐𝑐̇   = 𝜌𝜌𝑐𝑐 𝐴𝐴𝑐𝑐𝑐𝑐 𝑢𝑢𝑐𝑐

𝑘𝑘𝑘𝑘
4  𝑠𝑠
𝐴𝐴𝑐𝑐𝑐𝑐 =
𝑘𝑘𝑘𝑘 𝑚𝑚
1000  3 × 20  𝑠𝑠
𝑚𝑚
= 0.0002 𝑚𝑚2

Number of tubes required for heat transfer with dimension for length 1m, Inner- diameter
0.0525 m

𝑛𝑛 (𝜋𝜋𝜋𝜋𝜋𝜋) = 3.985 𝑚𝑚2
3.985
𝑛𝑛  =
𝜋𝜋  × 0.0525  × 1
= 24.161
≈ 24 𝑡𝑡𝑡𝑡𝑡𝑡𝑡𝑡𝑡𝑡

Number of tubes for Length 1m, diameter 0.0525m and single shell 2 pass heat exchanger:

2  × 𝑛𝑛 ×  𝜋𝜋𝜋𝜋𝜋𝜋  =  3.985 𝑚𝑚2
3.985 𝑚𝑚2
𝑛𝑛 =
2 × 𝜋𝜋 × 0.0525𝑚𝑚  × 1 𝑚𝑚
= 12.081
≈ 12 𝑡𝑡𝑡𝑡𝑡𝑡𝑡𝑡𝑡𝑡

Mass flow rate of water with heat transfer rate:

From the equation 𝑄𝑄  = 𝑚𝑚̇ 𝑐𝑐𝑝𝑝 Δ𝑇𝑇

The heat transfer rate is directly proportional to the mass flow rate of water through the tubes.

𝑘𝑘𝑘𝑘
Table 3: Data of mass flow rate of water, 𝑠𝑠
and heat transfer rate, kW

Mass flow rate of water, Heat transfer rate, kW

0 0
1 267.87
2 535.56
3 803.33
4 1071.10
5 1338.88
𝑘𝑘𝑘𝑘
Graph 1: Relationship between mass flow rate of water, 𝑠𝑠
with heat transfer rate, kW

Mass flow rate of water with heat transfer area:

𝑄𝑄 𝑚𝑚̇ 𝑐𝑐𝑝𝑝
From the equation 𝐴𝐴  =   𝑈𝑈𝑈𝑈Δ𝑇𝑇   = 𝑈𝑈 𝐹𝐹
the heat transfer area is directly proportional to the mass
flow rate of water through the tubes.

Table 4: Data of mass flow rate, kg⁄𝑠𝑠 and heat transfer area, 𝑚𝑚2

Mass flow rate of water,

𝑘𝑘𝑘𝑘
Heat transfer area, 𝑚𝑚2
𝑠𝑠
0 0
1 2.93
2 5.85
3 8.78
4 11.71
5 14.64
𝑘𝑘𝑘𝑘
Graph 2. Relationship between mass flow rate of water, 𝑠𝑠
with heat transfer area, 𝑚𝑚2

Convection heat transfer coefficient inside the tube:

Properties of water in tube at mean bulk fluid temperature, T(avg) = 57 °C, Pressure = 1.013
bar, assuming velocity of water is 20 m/s

𝜌𝜌 − 985.71 57 − 55 𝑘𝑘 − 0.649 57 − 55
= =
983.21 − 985.71 60 − 55 0.654 − 0.649 60 − 55
𝜌𝜌 − 985.71 𝑘𝑘 − 0.649
= 0.4 = 0.4
−2.5 0.005
𝜌𝜌 = 984.71 𝑘𝑘𝑘𝑘⁄𝑚𝑚3 𝑘𝑘 = 0.651 𝑊𝑊 ⁄𝑚𝑚 ∙ °𝐶𝐶

𝜇𝜇 − 0.000504 57 − 55
=
0.000466 − 0.000504 60 − 55 𝑃𝑃𝑃𝑃 − 3.25 57 − 55
=
𝜇𝜇 − 0.000504 2.98 − 3.25 60 − 55
= 0.4
−0.000038 𝑃𝑃𝑃𝑃 − 3.25
= 0.4
𝑘𝑘𝑘𝑘 −0.27
𝜇𝜇 = 0.0004888
𝑚𝑚 ∙ 𝑠𝑠 𝑃𝑃𝑃𝑃 = 3.142

𝜌𝜌𝜌𝜌𝜌𝜌
𝑅𝑅𝑅𝑅𝑤𝑤𝑤𝑤𝑤𝑤𝑤𝑤𝑤𝑤 =
𝜇𝜇
(984.71)(20)(0.0525)
=
0.0004888
= 2115273.12
1
For cross flow over cylindrical tube: 𝑁𝑁𝑁𝑁  =  𝐶𝐶 𝑁𝑁𝑅𝑅𝑅𝑅
𝑚𝑚
 𝑁𝑁𝑃𝑃𝑃𝑃
3

𝑁𝑁𝑁𝑁 =  0.023𝑅𝑅𝑒𝑒 0.8 (𝑃𝑃𝑃𝑃)0.3

= 0.023(2115273.12)0.8 (3.142)0.3
= 3725.5
𝑘𝑘
ℎ𝑖𝑖   =  𝑁𝑁𝑁𝑁 � �
𝑑𝑑
0.651
= 3725.5 � �
0.0525
𝑊𝑊
= 46196.2  2
𝑚𝑚 ∙ °𝐶𝐶

1
𝑈𝑈  =  
1 Δ𝑥𝑥 1
+ +
ℎ𝑖𝑖 𝑘𝑘 ℎ𝑜𝑜
1
=
1 (0.06033 − 0.0525) 1
46196.2 + 398 +
1586.35
𝑊𝑊
= 1488.76  2 𝑜𝑜
𝑚𝑚 .   𝐶𝐶

4.0 Discussion

Firstly, assuming the mass flow rate of water 𝑚𝑚̇ 𝑐𝑐 the heat gained by the water was calculated.
Assumed variable:

Table 3. Assumed Variable

Mass flow rate of steam, 𝑚𝑚𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠

̇ 𝑘𝑘𝑘𝑘
1.50588
𝑠𝑠
Mass flow rate of water, 𝑚𝑚𝑤𝑤𝑤𝑤𝑤𝑤𝑤𝑤𝑤𝑤
̇ 𝑘𝑘𝑘𝑘
4
𝑠𝑠
Pipe 2-in schedule 40 𝐼𝐼𝐼𝐼 = 0.0525𝑚𝑚,  𝑂𝑂𝑂𝑂 = 0.06033𝑚𝑚
Outer surface area(𝐴𝐴𝑜𝑜 ) , inner surface 𝐴𝐴𝑜𝑜 = 𝐴𝐴𝑖𝑖 = 𝐴𝐴𝑜𝑜 = 𝐴𝐴𝑙𝑙𝑙𝑙
area(𝐴𝐴𝑖𝑖 )  and log mean area(𝐴𝐴𝑙𝑙𝑙𝑙 ) 
Overall heat transfer coefficient, U 𝑊𝑊
1488.76
𝑚𝑚2 . °𝐶𝐶
Velocity of water, 𝑣𝑣 20 𝑚𝑚⁄𝑠𝑠

In this assignment, by assuming the mass flow rate of the steam 𝑚𝑚̇ℎ and the mass flow rate of
water 𝑚𝑚̇ 𝑐𝑐 , following the law of thermodynamics conservation of heat, the temperature
difference of steam inlet and outlet was calculated and from there the outlet temperature of
steam was determined.
The tube dimensions were assumed to be a 2-inch schedule 40 with an inner diameter of
0.0525m and an outer diameter of 0.06033m as it is an available type in the market and
commonly used for heat exchangers. This pipe was chosen because it can be utilized for a wide
range of purposes. This tube dimension is simple to install and requires little maintenance. This
makes it an excellent choice for shell and tube heat exchanger.

Copper tubes are frequently recommended due to their strength, corrosion resistance, and non-
toxicity. This pipe material can withstand pressures of up to 1,000 psi and last for up to decades.
Copper has a moderate corrosion rate and high melting point hence it is very effective for
minimizing energy loss during heat transfer. Therefore, hot water pipes and heat exchanger
tubes can be made using copper having high thermal conductivity, where high thermal
conductivity is directly proportional to heat flux. Copper is also readily available and used in
United states for thermal conductive appliances.

Thermophysical properties like density (𝜌𝜌), Thermal conductivity (𝑘𝑘), dynamic viscosity (𝜇𝜇) 
and Prandtl number (𝑃𝑃𝑃𝑃) of water and saturated steam were collected from water and steam
tables as mentioned in appendix, to find the convection heat transfer coefficient within the tube
for water and outside the tube for steam to make a better guess for the overall heat transfer
coefficient (𝑈𝑈) , which was then used to derive the heat transfer area. All the thermophysical
values are obtained using interpolation method from the steam table.

In the given shell-and-tube heat exchanger design scenario, opting for a cross-flow arrangement
offers several advantages. Cross-flow heat exchangers minimize the residence time of fluids
on the heat transfer surfaces due to the perpendicular flow of fluid streams, reducing the
likelihood of fouling and scaling. The compact design of cross-flow heat exchangers is
beneficial in situations with space constraints. Furthermore, cross-flow arrangements,
particularly in turbulent flow conditions, provide higher heat transfer rates due to enhanced
mixing and increased turbulence, resulting in improved heat transfer coefficients and overall
efficiency.

Cross-flow heat exchangers typically offer easier access for cleaning and maintenance
compared to other configurations, ensuring long-term performance and reliability. They also
experience lower pressure drops, especially on the shell side, which helps maintain system
performance and reduce energy consumption. Lastly, the flexibility of cross-flow heat
exchangers allows for easy adaptation to various flow rates and heat transfer requirements,
enabling customized solutions tailored to specific applications. Overall, the cross-flow
arrangement is a suitable choice for the given shell-and-tube heat exchanger design scenario,
offering performance, compactness, maintenance, and flexibility benefits. (Kakac et al, 2002)

Heat and momentum transfer in turbulent flow are influenced by flow velocity. In the case of
steam, high flow velocity results in increased momentum transfer due to the rapid movement
and interaction of fluid particles. However, the heat diffusivity of steam may not improve to
the same extent. Heat diffusivity depends on factors such as thermal conductivity, specific heat
capacity, density, and viscosity. Although high flow velocity in turbulent steam flow promotes
better mixing, steam's inherent properties, such as its low thermal conductivity and density,
limit its heat diffusivity. In summary, despite the enhanced momentum transfer in turbulent
steam flow, its heat diffusivity is limited by its intrinsic properties, leading to a less efficient
heat transfer compared to momentum transfer.

Thin-walled tube can be analysed without losing much accuracy as the thickness is small
compared to the tube diameter. So, the value of inner surface area, outer surface area and the
log mean area are very close to being equal. Assuming they are equal we calculate the overall
heat transfer coefficient.

𝑘𝑘𝑘𝑘
Based on the obtained graph 1, the relationship between mass flow rate of water, 𝑠𝑠 with heat
transfer rate, kW is directly proportional. The heat transfer rate, kW increases as the mass flow
𝑘𝑘𝑘𝑘
rate, 𝑠𝑠 increases. Next, corresponding to graph 2 has showed the relation between mass flow
𝑘𝑘𝑘𝑘
rate of water, 𝑠𝑠 with heat transfer area,𝑚𝑚2 is directly proportional. As the heat transfer area,𝑚𝑚2
𝑘𝑘𝑘𝑘
increases, so does the mass flow rate of water, 𝑠𝑠 .

In a shell-and-tube heat exchanger, the primary heat source (in this case, steam) transfers heat
to a secondary fluid (water) without direct contact between the fluids. The purpose of the heat
exchanger is to heat water from an initial temperature of 25°C to a final temperature of 89°C
using steam at 335°C. The steam enters the shell side with a velocity of 5 m/s. To achieve the
desired temperature, change efficiently, it is essential to increase the mass flow rate of water
with the heat transfer area and heat transfer rate. The following reasons justify this approach:

Improved Heat Transfer Efficiency: By increasing the mass flow rate of water, the rate of heat
transfer from the steam to the water will also increase. This is due to the fact that a higher flow
rate results in a greater temperature gradient between the fluids, resulting in a higher heat
transfer rate according to Fourier's Law of Heat Conduction.
Reduced Residence Time: A higher mass flow rate of water reduces the residence time of the
fluid within the heat exchanger. This means that the water will spend less time in contact with
the heat source, reducing the likelihood of fouling or scaling, which can negatively impact the
heat transfer efficiency and require additional maintenance.

Uniform Heating: Increasing the mass flow rate of water ensures a more uniform distribution
of heat throughout the heat exchanger. This results in more consistent and even heating of the
water, which is essential for achieving the desired final temperature of 89°C.

Enhanced Turbulence: A higher mass flow rate of water leads to increased turbulence within
the heat exchanger tubes. This turbulence enhances the convective heat transfer coefficient,
leading to a higher overall heat transfer rate between the steam and water.

Optimal Heat Exchanger Size: Increasing the mass flow rate of water and the heat transfer area
allows for the design of an appropriately sized heat exchanger. A larger heat transfer area
provides more surface area for heat exchange, which can improve efficiency and reduce the
temperature difference required between the steam and water. This results in a more compact
and cost-effective heat exchanger design.

Heat transfer coefficient: In a shell and tube heat exchanger, the heat transfer coefficient affects
the overall heat transfer rate between the two fluids, which in turn affects the temperature
difference between the fluids at the inlet and outlet of the heat exchanger. A higher heat transfer
coefficient can reduce the temperature difference between the fluids and increase the overall
efficiency of the heat exchanger. The heat transfer coefficient tells us the amount of heat being
transferred between a fluid and a solid surface by convection. Heat can move from the fluid to
the surface or vice versa. The heat transfer coefficient depends on the type of fluids, its flow
rate, and the shape of the heat exchanger. It is dependent on the fluid properties and the fluid
velocity while independent from the flow velocity. Being said, heat transfer coefficient is
directly proportional to the fluid velocity, an increase in the fluid velocity will result in an
increase in the heat transfer coefficient. The heat transfer coefficient that obtained were
1488.76 𝑊𝑊 ⁄𝑚𝑚2 ∙ °𝐶𝐶 with its velocity being 20 m/s. Hence, the heat transfer coefficient obtain
are considerably decent as it gives out approximately 1.4kW/m2.°C of heat being transfer with
the speed of 20m/s.

For safety impact, the thickness of the heat exchanger shell wall is 32 mm. Wall thickness in a
shell and tube heat exchanger is crucial for ensuring safety, structural integrity, and efficient
operation. This thickness provides a robust barrier that can withstand the system's operating
pressures and temperatures, protecting the heat exchanger from potential damage and ensuring
its longevity. Additionally, the thick shell wall improves insulation, minimizing heat loss to the
environment and enhancing the heat exchanger's overall efficiency. This reduced heat loss also
decreases radiant heat emission, lowering the risk of heat stroke for workers near the heat
exchanger and promoting a safer working environment. By considering the heat exchanger
safety precautions into account, an appropriate design condition for the shell and tube heat
exchanger was designed while adhering to the stated design constraints such as temperature
design, material compatibility, fluid nature, and dimension. This aids in avoiding ineffective
heat exchanger design, which can lead to mechanical integrity issues.

In conclusion, increasing the mass flow rate of water in a shell-and-tube heat exchanger, along
with the heat transfer area and heat transfer rate, leads to improved heat transfer efficiency,
reduced residence time, uniform heating, enhanced turbulence, and optimal heat exchanger
size. These factors ultimately contribute to a more effective and efficient heat exchanger design
that can achieve the desired temperature increase for the water.
5.0 References

1. Kilkovský, B., & Jegla, Z. (2016). Preliminary design and analysis of regenerative
heat exchanger. Chemical Engineering Transactions, 52, 655–660.
https://doi.org/10.3303/CET1652110
2. Bichkar, P., Dandgaval, O., Dalvi, P., Godase, R., & Dey, T. (2018). Study of Shell
and Tube Heat Exchanger with the Effect of Types of Baffles. Procedia
Manufacturing, 20, 195–200. https://doi.org/10.1016/J.PROMFG.2018.02.028
3. Cai, W., Sen, M., Yang, K. T., & Pacheco-Vega, A. (2005). Genetic-programming-
based symbolic regression for heat transfer correlations of a compact heat exchanger.
Proceedings of the ASME Summer Heat Transfer Conference, 4, 367–374.
https://doi.org/10.1115/HT2005-72293
4. Cengel, Y. A., & Ghajar, A. J. (2015). Heat and mass transfer: Fundamentals and
applications (5th ed.). McGraw-Hill Education.
5. https://www.rasmech.com/blog/plate-heat-exchanger/
6. Kakaç, S., & Liu, H. (2002). Heat exchangers: Selection, rating, and thermal design
(2nd ed.). CRC Press.
7. Perry, R. H., & Green, D. W. (Eds.). (2008). Perry's chemical engineers' handbook
(8th ed.). McGraw-Hill.
8. Sinnott, R. K., & Towler, G. P. (2009). Chemical engineering design: Principles,
practice and economics of plant and process design.

9. Engineers Edge. (2019). Overall heat transfer coefficient table charts and equation |

engineers edge | www.engineersedge.com. Engineersedge.com.

https://www.engineersedge.com/thermodynamics/overall_heat_transfer-table.htm
Saturated water table:

10. Evans, P. (2017, January 29). Properties of water at atmospheric pressure - The

Engineering Mindset. The Engineering Mindset.

https://theengineeringmindset.com/properties-of-water-atmospheric-pressure-

saturated-liquid/
Saturated steam table:

11. STEAM TABLES. (n.d.). Www.thermopedia.com.

https://www.thermopedia.com/content/1150/
12. Mokhena, T. C., Mochane, M. J., Sefadi, J. S., Motloung, S. V., & Andala, D. M.
(2018). Thermal Conductivity of Graphite-Based Polymer Composites. Impact of
Thermal Conductivity on Energy Technologies. doi:10.5772/intechopen.75676

Correction factor chart from lecture notes:

Appendix B: Declaration of Originality

Declaration of Originality

We, the undersigned members of this group [Group Name], declared that the report submitted is our
original work, and all sources of information and ideas have been duly acknowledged and referenced.

We affirm that:

1. This work has not been previously submitted for academic assessment or examination
purposes.
2. All sources used in the creation of this work has been appropriately cited and referenced
according to the guidelines provided.
3. We have not used any unauthorized assistance or materials in the creation of this work.
4. The work presented in this report is free from plagiarism, and any material reproduced from
other sources has been appropriately cited and referenced.
5. We understand that this work is our intellectual property and that we do not allow others to
copy, reproduce or distribute it in any form without our permission.
6. We understand that any breach of academic integrity in the creation of this work may lead to
disciplinary action, including expulsion from UCSI University.

Signed:

Full name of Group Member 1 (Student ID of Group Member 1)

Nowshad* 1001955556
Full name of Group Member 2 (Student ID of Group Member 2)
Yan Swee Cheiin 1002057448
Full name of Group Member 3 (Student ID of Group Member 3)
Lorna Ahlaami Binti Ramzan
Full name of Group Member 4 (Student ID of Group Member 4)
Gwendelyn Ho Hooi Sze 1001957287

Date: [2nd April 2023]

Page 4 of 5
Appendix C: Marking Rubric

Group members (Name & Student ID):

Nowshad*
……………………………………………………………………………………………………….. ( 1001955556 )
Yan Swee Cheiin
……………………………………………………………………………………………………….. ( 1002057448 )
Lorna Ahlaami Binti Ramzan
……………………………………………………………………………………………………….. ( 1001851777 )
Gwendelyn Ho Hooi Sze
……………………………………………………………………………………………………….. ( 1001957287 )

Rating 1 – Poor 2 – Satisfactory 3 – Good 4 – Excellent

Section Criteria 1 2 3 4
(weightage)
Introduction An introduction about the role of heat
(5%) exchanger in chemical industries and type
of heat exchanger available. Describe the
basic design of a shell and tube heat
exchanger.

Heat Design a suitable shell and tube heat

exchanger exchanger by providing a detailed
design (15%) calculation steps with logical assumptions.

Discussion of Discuss the results obtained and answer to

results (10%) the questions based on the design.

Total (%) / (120)

/ (30)

Page 5 of 5