Heat Exchange Design
and Optimization Project
Presented: May 6th, 2010
Professor: Mr. Toksoy
Group Members:
Nathan Dart
Andrew Kinney
Paul Thompson
Joe Sullivan
Christian Watness
Problem Statement:
Using a heat exchange reduce a liquid chemical by 20⁰C via
city water.
Design Criteria/Assumptions:
 Mass flow rate = 220,000 kg/hr
 Material properties of this chemical product can be approximated as
Cooling of the chemical product will be achieved by using treated city
City water is available at 20 ⁰C
Exit temperature of city water from the heat exchanger is a function of
the selected mass flow rate
Design Optimization Goals:
 Chemical must be cooled from 45⁰C to 25 ⁰C.
 Length of heat exchanger must not exceed 7 meters.
 Diameter of shell must not exceed 2 meters.
 Minimize heat exchanger weight.
 Minimize heat exchanger pressure drop.
Initial Parameters:
Funnel Effect
 Shell Material
City Water Flow
 Shell Thickness
Tube Length
 City Water Flow Rate
Tube Thickness
 Counter or Parallel
Tube Layout & Angle
Tube Material
 Shell ID
Tube Pitch
 Baffles – Yes or No
Shell Mass Flow
 Baffle Spacing
Main Effects Plot: Weight
Main Effects Plot: ΔP Shell
Main Effects Plot: ΔP Tube
Main Effects Plot: Q Calculated
Pareto Chart: Weight
Standardized Effects: Weight
Pareto Chart: ΔP Shell
Pareto Chart: ΔP Tube
Pareto Chart: Q Calculated
Standardized Effects : Q Calculated
Standardized Effects : Q Calculated
Optimized Results:
Heat Exchanger Inlet & Outlet Temperatures (Celsius)
Outlet Delta Bulk Wall
Tube 45.00
20.00 35.00 30.55
Shell 20.00
32.22 -12.22 26.11
Overall Heat Transfer Coefficient
U (Tube Outside Area) = 815.25 W/m2.C
Heat Transfer Rate
Desired Heat Transfer Rate = 5106263.80 W
Calculated Heat Transfer Rate = 5105087.64 W
Difference = 1176.16 W
Desired-to-Calculated Ratio =
HE Pressure Drop
Shell Side Delta-P = 12330.12 Pa
Shell Side Delta-P =
12.33 kPa
Tube Side Delta-P = 2412.77 Pa
Tube Side Delta-P =
2.41 kPa
Shell Side Pump Power = 0.31 kW
Tube Side Pump Power = 0.11 kW
Heat Exchanger Weight
Shell Weight
= 96.79 kg
Tube Weight
= 887.29 kg
Shell Fluid Weight = 1363.08 kg
Tube Fluid Weight = 873.20 kg
Total HE Weight
= 3220.36 kg
Material Selection Reasoning:
Cost of Shell (96.79 kg = 213.385 lbs)…
•Stainless Steal
1.04/lb = $221.92 Total
.84/lb = $179.24 Total
Cost of Tubes (N = 8,142)…
•Stainless Steal
Therefore, Aluminum was chosen for the tube material due to its
low weight. In addition, Stainless steal was chosen as the shell
material to provide a longer shell life.
Toksoy, John. ME 414 Thermal-Fluid Systems Design.
Department of Mechanical Engineering, IUPUI,
Indianapolis, IN, Spring 2010.
OnlineMetals.com. (n.d.). Retrieved May 6, 2010, from

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