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Optimizing Engine Oil Cooling in Textile Mills: A Twisted Shell and Tube Heat
Exchanger Approach

Technical Report · December 2023

DOI: 10.13140/RG.2.2.10033.56161

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 BANGLADESH UNIVERSITY OF ENGINEERING & TECHNOLOGY

Optimizing Engine Oil Cooling in Textile Mills: A

Twisted Shell and Tube Heat Exchanger Approach

Course Number: ME 310

Course Title: Thermo-Fluid System Design
Section: C
Group: C2-4

Submitted By
1910159 - Md. Saidur Rahman Tanvir
1910160 - Abdullah Al Mubin
1910162 - Khan Yishtiaq Raatul
1910165 - Tahasin Islam Rudra

Department of Mechanical Engineering, BUET

 TABLE OF CONTENTS
Copyright 1
Acknowledgment 2
Abstract 3
Introduction 4
Problem Statement 6
Objectives 7
Literature Review 8
Key Features 9
Limitations 11
Design Considerations 13
Analysis 14
Design Drawings 18
Manufactured Parts 19
Code For Calculation 20
Correlation Considerations 28
Calculation Strategy 29
Specifications 31
Fabrication Method 33
Costing 34
Pressure Testing 35
Future Plan 36
Conclusions 38
References 39

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 COPYRIGHT
Copyright© by Bangladesh University of Engineering and Technology. All rights
of the contents are reserved by Bangladesh University of Engineering and
Technology. Any parts of this document (electrical or mechanical or photocopy)
cannot be fully or partially rebuilt or reproduced without consent and written
permission from the authority of Bangladesh University of Engineering and
Technology.

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 ACKNOWLEDGEMENT
We wish to extend our deepest appreciation to all those who played integral roles
in the successful culmination of this project. Their steadfast support and invaluable
assistance have been instrumental in attaining our objectives.
Foremost, our sincere gratitude goes to:
Aminul Islam Olin
Lecturer, Dept. of Mechanical Engineering, BUET
Priom Das
Lecturer, Dept. of Mechanical Engineering, BUET
These esteemed individuals served as our project supervisors, offering unwavering
guidance, mentorship, and continuous feedback throughout this endeavor. Their
profound expertise and unwavering dedication were paramount in shaping the
trajectory of this project.
We also express our gratitude to the BUET Hydraulics Lab for their invaluable
assistance in conducting essential tests on our constructed model.
Furthermore, we are indebted to our fellow classmates who readily extended their
unconditional assistance in times of need. Their collective contributions and
support have been immensely valued.

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 ABSTRACT
This project report chronicles the development, fabrication, and performance
assessment of a distinctive shell and tube heat exchanger system. Featuring copper
tubes encased in a mild steel shell with a unique twist in tubing layout, the design
focuses on maximizing heat transfer effectiveness and thermal proficiency.
The selection of materials, incorporating copper tubes and a mild steel shell, was
deliberate to ensure longevity and resistance to corrosion, pivotal aspects in
industrial settings. The introduction of twisted pipes within the system is aimed at
augmenting turbulence and fostering improved heat transfer.
In this experimental arrangement, water circulated through the copper tubes, while
the shell side accommodated engine oil. Exhaustive performance evaluations were
conducted to appraise the efficiency of the heat exchanger under varied conditions.
The findings yield valuable insights into the heat transfer capabilities of this
innovative design.
This report furnishes a thorough scrutiny of the methodology, experimental
procedures, and outcomes, encompassing temperature profiles, heat transfer
coefficients, and overall efficiency. The gathered data and observations are
anticipated to enrich the broader comprehension of heat exchanger design and
operation, especially in applications involving dissimilar fluids.

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 INTRODUCTION
In textile mills, it is observed that the operating temperature of engine oil
frequently exceeds the recommended range of 115 to 120 degrees Celsius (239 to
248 degrees Fahrenheit). This temperature elevation primarily results from the
continuous operation of machinery and the consequent generation of friction
within the equipment. Textile machinery, encompassing spinning machines and
looms, is equipped with numerous moving components that engender friction,
leading to localized heating of vital parts like bearings and gears. Moreover, the
ambient temperature within the mill, particularly in regions with hot and humid
climates, can further contribute to elevated engine oil temperatures. The
ramifications of heightened oil temperature are significant, encompassing
alterations in oil viscosity, hastened oxidation and deterioration, diminished
lubrication efficacy, and a curtailed service life of the oil. To counteract these
issues, textile mills must address the underlying causes by instituting sound
maintenance protocols, monitoring machinery temperatures, selecting appropriate
engine oils, ensuring adequate ventilation and cooling, and conducting regular
inspections of machinery for wear and damage attributable to temperature-related
factors. These measures are imperative for preserving machinery functionality and
longevity while minimizing downtime and maintenance expenditures.

A shell and tube heat exchanger presents a viable solution for alleviating escalated
engine oil temperatures in textile mills by offering an efficient means of cooling
the engine oil. It functions as a heat transfer apparatus wherein the heated engine
oil traverses through the tubes, while a cooling medium (such as water) circulates
around the tubes within the shell. This configuration facilitates the transfer of
surplus heat from the engine oil to the cooling medium, effectively reducing the
oil's temperature.

A shell and tube heat exchanger comprises a shell, an outer vessel, and an array of
tubes contained within. Typically, cylindrical or rectangular, the shell is
constructed from materials like carbon steel or mild steel. It features inlet and
outlet ports for two distinct fluids: one coursing inside the tubes and the other
enveloping the exterior of the tubes. Within the shell, baffles or partitions are
situated to guide the flow of the external fluid, maximizing the efficiency of heat
transfer. Conversely, the tubes, typically composed of materials such as copper or
mild steel, are arranged in assorted configurations, including straight tubes, U-

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tubes, or helical coils, contingent on the specific requirements for heat transfer.
The process of heat transfer encompasses two fluids passing adjacent to each other:
one within the tubes and the other outside them. Heat is transferred through the
tube walls from one fluid to the other, resulting in a modification of temperature
for both fluids, enabling heating or cooling as necessitated.

Shell and tube heat exchangers find widespread application in diverse industries
due to their efficiency and adaptability. They can accommodate disparate
temperature ranges and fluid compositions, rendering them apt for use in HVAC
systems, chemical processing, power generation, and various other domains. These
heat exchangers can be customized with an array of options to cater to precise
operational requisites.

Shell and tube heat exchangers, distinguished by their efficient heat transfer
capabilities and robust construction, are exceptionally versatile and find extensive
use across various industrial domains. Common applications include HVAC
systems, power generation
facilities, chemical processing plants, petrochemical industry operations, food and
beverage processing units, oil and gas facilities, marine and shipbuilding ventures,
pharmaceutical production, wastewater treatment facilities, aerospace enterprises,
automotive industry operations, and textile manufacturing processes.

Our heat exchanger design integrates a shell and tube configuration, distinguished
by unique attributes. Within the mild steel shell, a cluster of twisted copper tubes
has been implemented. These spiraled tubes play a pivotal role in intensifying
turbulence and facilitating effective heat transfer. The fluid on the tube side, in this
case water, circulates through these copper conduits, while the fluid on the shell
side, engine oil, circulates around the tubes. This arrangement engenders an
efficient exchange of heat between the two fluids, thereby enabling effective
cooling or heating as dictated by our specific application. The deployment of
twisted copper tubes augments heat transfer efficiency and guarantees a compact
and efficient heat exchanger design, thereby optimizing its performance.

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 PROBLEM STATEMENT
In textile mills, the waste water temperature at the outlet after the dyeing process in
a bath is 60°C. This water is then recycled for further use. In a different context,
for safety reasons, the acceptable temperature for engine oil in machineries is
approximately 120°C. Let's consider a specific machine located adjacent to the
bath. In this scenario, we must cool down the engine oil if its temperature exceeds
120°C by utilizing the heat from the waste water. The provided data is as follows:

Shell Side
Inlet Temperature 120 °C
Mass Flow Rate 1.00 Kg/s
Inside Diameter 6.00 inches
Number of Baffles 4
Baffle Spacing 9.00 inches

Tube Side
Inlet Temperature 60 °C
Outer Diameter 0.50 inches
Inner Diameter 0.33 inches
Number of Tubes 10
Tube Passes 1
Tube Length 3.00 feet
Tube Layout 90°

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 OBJECTIVES
The aims of this project encompass:

• Elevate thermal efficiency

• Integrate twisted pipes into conventional STHX
• Determine the optimal structure for appropriate pressure differentials across
both the shell and twisted tube sides
• Select fitting materials and designs for peak performance
• Facilitate easy installation, maintenance, and cleaning
• Iteratively compute the final design parameters
• Create a model using CAD
• Fabricate a prototype using accessible resources in accordance with the final
design and calculations.

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 LITERATURE REVIEW

The inspiration for employing twisted tubes was drawn from the research paper
“Yu, C., Zhang, H., Wang, Y., Zeng, M., & Gao, B. (2020). Numerical study on
turbulent heat transfer performance of twisted oval tube with different cross
sectioned wire coil. Case Studies in Thermal Engineering.” This study delves into
a numerical exploration of the thermal-hydraulic characteristics of a twisted oval
tube fitted with three wire coils of varying cross sections (circular, equilateral, and
square) under turbulent flow conditions. Factors such as geometric shape, rotation
direction, and orientation of the wire coils' cross sections were also investigated.
The analysis employs a polyhedral mesh and employs water as the working fluid.
The findings were compared with those obtained from a twisted oval tube without
wire coils. The results indicate a notable improvement in heat transfer rate and
pump consumption when utilizing both twisted tubes and wire coils in tandem,
albeit with a slight decrease in the Performance Evaluation Criterion (PEC).
Among the wire coil configurations, the equilateral cross sectioned wire coil
demonstrated the most favorable thermal-hydraulic performance. This
configuration exhibited an average increase ratio of Nu by 45.92% and an average
f of 674.86% when compared to the twisted oval tube without wire coils.

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 KEY FEATURES
A twisted shell-and-tube heat exchanger is a variation of the traditional shell-and-
tube heat exchanger design. In a twisted shell-and-tube heat exchanger, the tubes
are arranged in a helical or twisted pattern within the shell. This design offers some
unique advantages over conventional straight-tube designs.
The operating principle of a twisted shell-and-tube heat exchanger is similar to that
of a regular shell-and-tube heat exchanger, but the twisted arrangement of the tubes
provides some specific benefits:
• Enhanced Heat Transfer: The twisted configuration promotes turbulent
flow, which enhances heat transfer rates. This means that the heat exchanger
can achieve higher levels of thermal efficiency compared to a straight-tube
design.

• Self-Cleaning Effect: The helical arrangement of the tubes can help prevent
fouling and scaling. As the fluid flows through the helical path, it creates a
scrubbing action, reducing the likelihood of deposits accumulating on the
tube surfaces.

• Compact Design: Twisting the tubes allows for a more compact heat
exchanger. This can be particularly advantageous in situations where space
is limited.

• Reduced Pressure Drop: The helical arrangement can lead to lower

pressure drops compared to straight-tube designs. This means that the pump
requirements for the fluid flow are reduced, resulting in energy savings.

• Variable Flow Paths: The twisted configuration can allow for different
flow paths within the heat exchanger. This flexibility in flow patterns can be
beneficial for specific applications where optimized heat transfer is critical.

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 • Improved Heat Distribution: The helical pattern helps in distributing the
heat more evenly across the entire heat exchanger, reducing the risk of hot
spots and ensuring a more uniform temperature distribution.

• Higher Turbulence: The twisted arrangement induces higher levels of

turbulence in the fluid flow. This turbulence promotes better mixing and
helps to break up boundary layers, further enhancing heat transfer.

It's worth noting that while twisted shell-and-tube heat exchangers offer these
advantages, they may also have some limitations, such as potential challenges in
manufacturing and cleaning compared to traditional designs. The suitability of a
twisted shell-and-tube heat exchanger for a specific application depends on various
factors including the nature of the fluids involved, operating conditions, and space
constraints.

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 LIMITATIONS
While twisted shell-and-tube heat exchangers offer various advantages, they also
come with some limitations. Here are some of the potential drawbacks associated
with this design:
• Complex Manufacturing: Fabricating and assembling twisted tube bundles
can be more complex and time-consuming compared to traditional straight-
tube designs. This can potentially lead to higher production costs.

• Limited Availability: Twisted shell-and-tube heat exchangers may not be as

readily available as standard designs, which could lead to longer lead times
for procurement and replacement parts.

• Cleaning Challenges: The helical arrangement of tubes can make cleaning

more difficult compared to straight-tube exchangers. This could be a concern
in applications where fouling or scaling is a common issue.

• Potential for Vibration Issues: Depending on the design and operating

conditions, the helical arrangement may introduce a potential for vibration or
resonance, which could lead to mechanical issues or maintenance
challenges.

• Specialized Applications: Twisted shell-and-tube heat exchangers may be

best suited for specific applications where their unique benefits are most
valuable. They may not be the optimal choice for all heat exchange
scenarios.

• Non-standard Sizing: Twisted shell-and-tube heat exchangers may not

conform to standard sizing conventions, which could potentially lead to
challenges in retrofitting or replacing them in existing systems.

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 • Limited Research and Testing: Compared to traditional designs, there may
be fewer established guidelines, standards, and extensive research available
for twisted shell-and-tube heat exchangers. This may require more careful
consideration during design and testing phases.

• Higher Pressure Drop in Some Cases: While twisted designs can offer
lower pressure drops in many situations, in certain scenarios, especially with
highly viscous fluids, they may exhibit higher pressure drops compared to
straight-tube exchangers.

It's important to note that the suitability of a twisted shell-and-tube heat exchanger
for a specific application depends on various factors, including the nature of the
fluids being processed, operating conditions, available space, and specific
performance requirements. Engineers and designers should carefully evaluate these
factors when considering the use of a twisted shell-and-tube heat exchanger in a
given application.

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 DESIGN CONSIDERATIONS
FLUID ALLOCATION
It is typically recommended to prioritize the use of the more fouling-resistant fluid
in the tube section. However, in our specific case, we took a different approach.
This decision was influenced by the fact that the correlations for Nusselt number
and friction factor for twisted tube available to us were derived solely from
numerical analyses conducted on water. Consequently, we allocated engine oil to
the shell side and utilized water for the tube side.

MATERIAL SELECTION
Copper was selected as the tube material due to its exceptional conductivity and
ductility, attributes that are also advantageous for bending and shaping processes.
For the shell material, we opted for mild steel, primarily because of its wide
availability from manufacturers.

DIMENSION ADJUSTMENT
To streamline our approach and minimize potential complexities, we maintained
the majority of the dimensions at a fixed value. This strategic choice aligns our
problem statement more closely with a rating problem rather than a design
problem.

SHELL SIDE MASS FLOW RATE

In the shell side, a range of allowable mass flow rates, from 0.1 Kg/s to 2.1 Kg/s,
was considered for our problem statement. The reason behind this choice will be
further explained in the analysis section.

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 ANALYSIS
Variation of Heat Duty with Shell Side Mass Flow Rate
In the realm of heat exchange dynamics, it is established that augmenting mass
flow rates generally increases a heat exchanger's heat transfer capacity. This
principle applies to our case as well, where elevating the shell-side mass flow rate,
up to 2 Kg/s, notably enhances the heat duty. However, beyond this threshold, the
rate of increase stabilizes, indicating diminishing returns. It is crucial to note that
the relationship between mass flow rate and heat duty is not strictly linear; beyond
a certain point, further increases in flow do not proportionally enhance heat duty.
Pushing for an excessively high shell-side mass flow rate can lead to amplified
pressure drops within the shell side, necessitating higher pumping power and
subsequently elevating energy consumption. This could render the endeavor
economically impractical. Thus, a discerning assessment of specific heat transfer
requirements should guide the selection of the optimal mass flow rate for the shell
side, ensuring a balance between enhanced thermal performance and economic
viability.

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Variation of Shell Side Pressure Drop with Shell Side Mass Flow Rate
Even when subjecting the shell side to an elevated mass flow rate, meticulous
analysis reveals that the pressure drop experienced within the system adheres
comfortably to the predefined permissible limits. This substantiates the structural
integrity and operational safety of our meticulously designed heat exchanger, even
under the increased demand imposed by higher mass flow rates on the shell side.
Consequently, we can confidently affirm that the heat exchanger is aptly equipped
to handle and facilitate the augmented mass flow rates on the shell side without
compromising its safety or performance parameters. This attests to the robustness of
our design, ensuring that it aligns seamlessly with the projected operational
requirements.

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Variation of Tube Side Pressure Drop with Shell Side Mass Flow Rate
Regrettably, upon rigorous examination, it has been determined that the pressure
drop experienced in the tube side surpasses the established threshold for shell side
mass flow rates surpassing 2.1 Kg/s. This compelling finding necessitates a judicious
adjustment in our operational parameters to ensure safety and efficiency.
Consequently, for precautionary measures and to uphold operational integrity, it is
imperative that the mass flow rate within the shell side is rigorously maintained at
or below 2.1 Kg/s. This calculated limitation is crucial in guaranteeing that the heat
exchanger functions optimally while safeguarding against any potential operational
hazards that may arise from excessive pressure drops in the tube side.

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Comparing Key Parameters: Straight Vs. Twisted Tubes
The presented graphs unmistakably illustrate that in the instance of a twisted
configuration of tubes, key parameters such as heat duty, Nusselt number, friction
factor, and tube side pressure drop exhibit higher values compared to those
observed in the case of a straight tube configuration. This discernible trend
underscores the enhanced heat transfer capabilities and altered fluid dynamics
inherent to the twisted tube design, leading to notable variations in performance
metrics when compared to the conventional straight tube counterpart.

Table: Change in Key Parameters

Change in Heat Duty +15.4%
Change in Tube Side Nusselt Number +13.92%
Change in Tube Side Friction Coefficient +50%
Change in Tube Side Pressure Drop +21.8%

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 DESIGN DRAWINGS
Software used: SolidWorks

Fig 1: Assembly (Without Shell)

Fig 2: Assembly (With Shell)

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 MANUFACTURED PARTS

Fig 3: Tubes with Baffles

Fig 4: Tube sheet Fig 5: Shell

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 CODE FOR CALCULATION
Programming Language Used: Python

import math
import numpy as np

# Data (Fouling)
Rf_i = 0.00035 # m^2.K/W
Rf_o = 0.00088 # m^2.K/W

# Unit Conversion Functions

def m2ft(meters):
feet = meters * 3.28084
return feet

def ft2m(feet):
meters = feet * 0.3048
return meters

def in2m(inches):
meters = inches * 0.0254
return meters

def m2in(meters):
inches = meters / 0.0254
return inches

def sqm2sqft(square_meters):
square_feet = square_meters * 10.7639
return square_feet

# Assumed Initial Values

Ts_out = 110 # °C
Tt_out = 65 # °C
Uo = 150 # W/m^2.K
L = ft2m(3) # m
ODt = in2m(0.5) # m
IDt = in2m(0.33) # m
PR = 1.25
Pitch_type = "square"
CL = 1
CTP = 0.93
Nt = 10

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Nb = 4
Np = 1
B = in2m(9) # m
Ds = in2m(6) # m

# Derived Initial Values

Ki = 1/4 * IDt**2
Ko = 1/4 * ODt**2
percentage = 0.25
a = IDt * percentage
b = Ki / a

# Initialize the variables

iterations = 0
max_iterations = 1000
convergence_limit = 1E-5
red_flag = "off"

## Hydraulic Diameter for Tube

Dht = (4*a*b) / (3*(a+b) - math.sqrt((3*a+b)*(a+3*b)))

## Equivalent Diameter for Tube

Det = 2*math.sqrt(a*b)

## Equivalent for ODt

Det_o = Det + ODt - IDt

## Pitch Length
Pt = PR * Det_o

## Hydraulic Diameter for Shell

if Pitch_type == "square":
Dhs = (4*Pt**2) / (math.pi * Det_o) - Det_o
elif Pitch_type == "triangular":
Dhs = (2*math.sqrt(3)*Pt**2) / (math.PI * Det_o) - Det_o

## Equivalent Diameter for Shell

Des = Dhs

## Clearance Length
C = Pt - Det_o

## Bundle Cross-flow Area

As = (Ds * C * B) / Pt

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## Heat Transfer Area
Ao = Nt * math.pi * Det_o * L

## Total Tube Inner Surface Area

Ai = Nt * math.pi * Det * L

## Total x-section Area

At = (Nt / Np) * (math.pi / 4) * Det**2

while iterations < max_iterations:

# Property Tables
## Properties of Saturated Water
T_w = [5, 10, 15, 20, 25, 30, 35, 40, 45, 50, 55, 60, 65, 70] # °C
rho_w = [999.9, 999.7, 999.1, 998, 997, 996, 994, 992.1, 990.1, 988.1,
985.2, 983.3, 980.4, 977.5] # Kg/m^3
Cp_w = [4205, 4194, 4185, 4182, 4180, 4178, 4178, 4179, 4180, 4181, 4183,
4185, 4187, 4190] # J/KgK
K_w = [0.571, 0.580, 0.589, 0.598, 0.607, 0.615, 0.623, 0.631, 0.637,
0.644, 0.649, 0.654, 0.659, 0.663] # W/mK
u_w = np.array([1.519, 1.307, 1.138, 1.002, 0.891, 0.798, 0.720, 0.653,
0.596, 0.547, 0.504, 0.467, 0.433, 0.404])*1E-3 # Pas
Pr_w = [11.2, 9.45, 8.09, 7.01, 6.14, 5.42, 4.83, 4.32, 3.91, 3.55, 3.25,
2.99, 2.75, 2.55]

## Properties of Engine Oil

T_o = [77, 87, 97, 107, 117, 127] # °C
rho_o = [853.9, 847.8, 841.8, 836, 830.6, 825.1] # Kg/m^3
Cp_o = [2118, 2161, 2206, 2250, 2294, 2337] # J/KgK
K_o = np.array([138, 138, 137, 136, 135, 134])*1E-3 # W/mK
u_o = np.array([3.56, 2.52, 1.86, 1.41, 1.1, 0.874])*1E-2 # Pas
Pr_o = [546, 395, 300, 233, 187, 152]

## Properties of Tube Wall (Copper)

T_wall = [30, 90, 150]
k_wall = [400.7, 395.9, 391.4]

# Data (Shell Side - Engine Oil)

Ts_in = 120 # °C
Ts_film = np.mean([Ts_in, Ts_out]) # °C
m_s = 1 # Kg/s
Ks = np.interp(Ts_film, T_o, K_o) # W/mK
rho_s = np.interp(Ts_film, T_o, rho_o) # Kg/m^3
Cp_s = np.interp(Ts_film, T_o, Cp_o) # J/KgK

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us = np.interp(Ts_film, T_o, u_o) # Pas
Pr_s = np.interp(Ts_film, T_o, Pr_o)
delta_Ps_max = 70E3 # Pa

# Data (Tube Side - City Water)

Tt_in = 60 # °C
Tt_film = np.mean([Tt_in, Tt_out]) # °C
Kt = np.interp(Tt_film, T_w, K_w) # W/mK
rho_t = np.interp(Tt_film, T_w, rho_w) # Kg/m^3
Cp_t = np.interp(Tt_film, T_w, Cp_w) # J/KgK
ut = np.interp(Tt_film, T_w, u_w) # Pas
ub = ut # Pas
Pr_t = np.interp(Tt_film, T_w, Pr_w)
delta_Pt_max = 70E3 # Pa

# Data (Tube Wall)

Tw = np.mean([Ts_film, Tt_film]) # °C
K_wall = np.interp(Tw, T_wall, k_wall) # W/mK
uw = np.interp(Tw, T_w, u_w) # Pas

# Mass Flow Rate in Tube Side

m_t = (m_s * Cp_s * (Ts_in - Ts_out)) / (Cp_t * (Tt_out - Tt_in))

## Fluid Velocity
Vt = m_t / (rho_t * At)

## Reynold's Number for Heat Transfer

Re_t = (rho_t * Vt * Det) / ut
if Re_t < 2300:
flow_type_t = "Laminar"
else:
flow_type_t = "Turbulent"

## Reynold's Number for Pressure Drop

Re_t_p = (rho_t * Vt * Dht) / ut
if Re_t_p < 2300:
flow_type_t = "Laminar"
else:
flow_type_t = "Turbulent"

## Friction Coefficient
if 2300 <Re_t_p < 1E6:
ft = 0.0228 + 16.5 / (Re_t_p**0.84)
else:
print(f"The chosen values are not correct. Choose different value.")

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 print(f"If you change the temperatures, you will need to change
thermal properties accordingly")
print(f"Or you can change any of the mass flowrate as well, the other
mass flowrate will be affected by it")
print(f"Or you can change the assumed initial values")
red_flag = "on"
break

## Pressure Drop
delta_Pt = Np*(ft*(L/Dht) + 4)*(1/2*rho_t*Vt**2)
if delta_Pt >= delta_Pt_max:
print(f"Pressure drop for tube side exceeds allowable limit.")
print(f"The chosen values are not correct. Choose different value.")
print(f"If you change the temperatures, you will need to change
thermal properties accordingly")
print(f"Or you can change any of the mass flowrate as well, the other
mass flowrate will be affected by it")
print(f"Or you can change the assumed initial values")
red_flag = "on"
break

## Nusselt Number
if 2300 <Re_t < 1E6:
Nu_t = 0.0391 *(Re_t**0.762) * (Pr_t**0.4)
else:
print(f"The chosen values are not correct. Choose different value.")
print(f"If you change the temperatures, you will need to change
thermal properties accordingly")
print(f"Or you can change any of the mass flowrate as well, the other
mass flowrate will be affected by it")
print(f"Or you can change the assumed initial values")
red_flag = "on"
break

## Convectional Heat Transfer Coefficient

hi = (Nu_t * Kt) / Det

# Shell-Side
## Velocity of Fluid
Vs = m_s / (rho_s*As)

## Reynold's Number
Re_s = (rho_s * Vs * Dhs) / us
if Re_s < 2300:

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 flow_type_s = "Laminar"
else:
flow_type_s = "Turbulent"

## Friction Coefficient
fs = math.exp(0.576-0.19*math.log(Re_s))

## Pressure Drop
delta_Ps = fs*(Nb+1)*(Ds/Dhs)*(1/2*rho_s*Vs**2)
if delta_Ps >= delta_Ps_max:
print(f"Pressure drop for shell side exceeds allowable limit.")
print(f"The chosen values are not correct. Choose different value.")
print(f"If you change the temperatures, you will need to change
thermal properties accordingly")
print(f"Or you can change any of the mass flowrate as well, the other
mass flowrate will be affected by it")
print(f"Or you can change the assumed initial values")
red_flag = "on"
break

## Nusselt Number
Nu_s = 0.36 * Re_s**0.55 * Pr_s**(1 / 3)

## Convectional Heat Transfer Coefficient

ho = (Nu_s * Ks) / Des

# Overall Heat Transfer Coefficient After Iteration

Wall_resistance = math.log(ODt / IDt) / (2 * math.pi * K_wall * L)
Uo_new = 1 / (Ao * (1 / (hi * Ai) + Wall_resistance + 1 / (ho * Ao) +
Rf_i / Ai + Rf_o / Ao))

# Heat Capacity Ratio

Cs = m_s*Cp_s
Ct = m_t*Cp_t
C_max = max(Cs, Ct)
C_min = min(Cs, Ct)
c = C_min / C_max

# Net Transfer Unit

NTU = Uo*Ao/C_min

# Effectiveness
sq = math.sqrt(1 + c**2)
ex = math.exp(-NTU * sq)
eff = 2*(1 + c + sq * ((1 + ex)/(1 - ex)))**-1

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 # Maximum Temperature Difference
T_max = max(Ts_in, Ts_out, Tt_in, Tt_out)
T_min = min(Ts_in, Ts_out, Tt_in, Tt_out)
delta_T_max = T_max - T_min

# Maximum Heat Duty

Q_max = C_min*delta_T_max

# Actual Heat Duty

Q = eff * Q_max

# Outlet Temperatures
Ts_out_new = Ts_in - Q / Cs
Tt_out_new = Tt_in + Q / Ct

# Check for convergence

if abs(Ts_out_new - Ts_out) < convergence_limit and abs(Tt_out_new -
Tt_out) < convergence_limit and abs(Uo_new - Uo) < convergence_limit:
break

# Update Ts_out and Tt_out for the next iteration

Ts_out = Ts_out_new
Tt_out = Tt_out_new

# Update Uo for the next iteration

Uo = Uo_new

iterations += 1

# Display the results with proper units

if red_flag == "on":
print(f"Faulty Design. Follow the instructions above.")
else:
print(f"-----Complete Specification-----")
print(f"Overall Heat Transfer Coefficient (Uo): {math.ceil(Uo)} W/m^2.K")
print(f"Heat Duty (Q): {Q/1E3:.2f} KW")

print("\n--Shell Side Specification--")

print(f"Inlet Temperature (Ts_in): {Ts_in} °C")
print(f"Outlet Temperature (Ts_out): {Ts_out:.2f} °C")
print(f"Mass Flow Rate (m_s): {m_s:.2f} Kg/s")
print(f"Fluid Velocity (Vs): {Vs:.2f} m/s")
print(f"Pressure Drop (ΔPs): {delta_Ps/1000:.4f} kPa")
print(f"Inside Diameter (Ds): {m2in(Ds):.2f} inch")
print(f"Hydraulic Diameter (Dhs): {m2in(Dhs):.2f} inch")

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 print(f"Equivalent Diameter (Des): {m2in(Des):.2f} inch")
print(f"Number of Baffles (Nb): {math.ceil(Nb)}")
print(f"Baffle Spacing (B): {m2in(B):.2f} inch")
print(f"Bundle Cross-flow Area (As): {sqm2sqft(As):.4f} ft^2")
print(f"Pitch Length (Pt): {m2in(Pt):.2f} inch")
print(f"Clearance Length (C): {m2in(C):.2f} inch")
print(f"Convectional Heat Transfer Coefficient (ho): {math.ceil(ho)}
W/m^2.K")
print(f"Reynold's Number (Re_s): {math.ceil(Re_s)}")
print(f"Nusselt Number (Nu_s): {math.ceil(Nu_s)}")
print(f"Flow Type: {flow_type_s}")
print(f"Friction Coefficient (fs): {fs:.2f}")

print("\n--Tube Side Specification--")

print(f"Inlet Temperature (Tt_in): {Tt_in} °C")
print(f"Outlet Temperature (Tt_out): {Tt_out:.2f} °C")
print(f"Mass Flow Rate (m_t): {m_t:.2f} Kg/s")
print(f"Fluid Velocity (Vt): {Vt:.2f} m/s")
print(f"Pressure Drop (ΔPt): {delta_Pt/1000:.4f} kPa")
print(f"Outer Diameter (ODt): {m2in(ODt):.2f} inch")
print(f"Inner Diameter (IDt): {m2in(IDt):.2f} inch")
print(f"Hydraulic Diameter (Dht): {m2in(Dht):.2f} inch")
print(f"Equivalent Diameter (Det): {m2in(Det):.2f} inch")
print(f"Number of Tubes (Nt): {math.ceil(Nt)}")
print(f"Tube Passes (Np): {Np}")
print(f"Tube Length (L): {m2ft(L):.2f} feet")
print(f"Heat Transfer Area (Ao): {sqm2sqft(Ao):.4f} ft^2")
print(f"Total Inner Surface Area (Ai): {sqm2sqft(Ai):.4f} ft^2")
print(f"Total x-section Area (At): {sqm2sqft(At):.4f} ft^2")
print(f"Pitch Ratio (PR): {PR:.2f}")
print(f"Tube Layout = 90°")
print(f"Convectional Heat Transfer Coefficient (hi): {math.ceil(hi)}
W/m^2.K")
print(f"Reynold's Number for Heat Transfer (Re_t): {math.ceil(Re_t)}")
print(f"Reynold's Number for Pressure Drop (Re_t_p):
{math.ceil(Re_t_p)}")
print(f"Nusselt Number (Nu_t): {math.ceil(Nu_t)}")
print(f"Flow Type: {flow_type_t}")
print(f"Friction Coefficient (ft): {ft:.2f}")

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 CORRELATION CONSIDERATIONS
The steady dimensionless mathematic equations for continuity, momentum and
energy are as follows-
Continuity equation:
∂(𝜌𝑢𝑗 )
=0
∂𝑥𝑗

Momentum equation:
∂(𝜌𝑢𝑖 𝑢𝑗 ) ∂𝑝 ∂ ∂𝑢𝑖 ∂𝑢𝑗
=− + (𝜇𝑒𝑓𝑓 ( + ))
∂𝑥𝑗 ∂𝑥𝑖 ∂𝑥𝑗 ∂𝑥𝑗 ∂𝑥𝑖

Energy equation:
∂(𝜌𝑐𝑝 𝑇𝑢𝑗 ) ∂ ∂𝑇
= (𝜆𝑒𝑓𝑓 ( ))
∂𝑥𝑗 ∂𝑥𝑗 ∂𝑥𝑗

For the shell side, we applied the following correlations-

Nusselt Number:
𝑁𝑢 = 0.36Re0.55
𝑠 ⁡ Pr1/3

Friction Factor:
𝑓𝑠 = exp⁡[0.576 − 0.19 ln(𝑅𝑒𝑠 )]

For the twisted tube side, we applied the following correlations-

Nusselt Number:
𝑁𝑢 = 0.0391𝑅𝑒 0.762Pr 0.4

Friction Factor:
16.5
𝑓 = 0.0228 +
𝑅𝑒 0.84

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 CALCULATION STRATEGY
The entire calculation was an iterative approach. The steps in a single iteration is
given below:
Step 1: Fixing basic dimensions
In the initial phase, we established the following dimensions in order to approach
our challenge from a rating perspective rather than a design standpoint-
• Number of tubes, Nt = 10
• Number of baffles, Nb = 4
• Tube length, L = 3 ft
• Shell inside diameter, Ds = 6 inch
• Baffle spacing, B = 9 inch

Step 2: Assuming outlet temperatures

To ascertain the film temperature, we made the assumption of outlet temperatures
for both the shell and tube sides.
𝑇𝑠, 𝑖𝑛⁡ + ⁡𝑇𝑠, 𝑜𝑢𝑡
𝑇𝑠, 𝑓𝑖𝑙𝑚 = ⁡
2
𝑇𝑡, 𝑖𝑛⁡ + ⁡𝑇𝑡, 𝑜𝑢𝑡
𝑇𝑡, 𝑓𝑖𝑙𝑚 = ⁡
2

Step 3: Determining necessary thermal properties

We determined the thermal properties for both shell and tube side given below-
Properties Shell Side Tube Side
Cp (J/Kg.K) 2302.27 4185.21
𝜇 (W/m.K) 0.0105 0.0004
K (W/m.K) 0.134 0.654
Pr 180.26 2.964
𝜌 (kg/m3) 829.54 982.98

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Step 4: Determining pressure drop
Following an extensive calculation, we derived the pressure drop in both sides
using the following equations-
Shell side:
𝐷𝑠 1
Δ𝑃𝑠 = 𝑓𝑠 (𝑁𝑏 + 1) ( 𝜌𝑠 𝑉𝑠2 )
𝐷𝑒 2
Tube Side:
𝐿 1
Δ𝑃𝑡 = 𝑁𝑝 (𝑓𝑡 + 4) ( 𝜌𝑡 𝑉𝑡2 )
𝐼𝐷𝑡 2

Step 5: Determining overall heat transfer coefficient

We calculated the overall heat transfer coefficient using the following equation:
1
𝑈𝑜 =
𝐴𝑜 1 𝐴𝑜 𝑅𝑓𝑖 𝑅𝑓𝑜 1
+ + 𝐴𝑜 𝑅𝑤 + +
𝐴𝑖 𝜂𝑖 ℎ𝑖 𝜂𝑖 𝐴𝑖 𝜂 𝑜 𝜂 𝑜 ℎ𝑜

Step 6: Determining heat duty

We calculated the heat duty using effectiveness NTU approach-
𝑄⁡ = ⁡𝜀 ∗ 𝑄𝑚𝑎𝑥

Step 7: Correcting outlet temperatures

𝑄
𝑇𝑠_𝑜𝑢𝑡⁡ = ⁡𝑇𝑠_𝑖𝑛⁡ − ⁡
𝐶𝑠
𝑄
𝑇𝑡_𝑜𝑢𝑡⁡ = ⁡𝑇𝑡_𝑖𝑛⁡ + ⁡
𝐶𝑡
The iterations stopped when the value of outlet temperatures and overall heat
transfer coefficient converged.

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 SPECIFICATIONS
Overall Heat Transfer Coefficient (Uo): 269 W/m2.K
Heat Duty (Q): 5.7 kW

Shell Side
Inlet Temperature (Ts,in): 120 °C
Outlet Temperature (Ts,out): 117.52 °C
Mass Flow Rate (ms): 1.00 Kg/s
Fluid Velocity (Vs): 0.17 m/s
Pressure Drop (ΔPs): 0.5044 kPa
Inside Diameter (Ds): 6.00 inch
Hydraulic Diameter (Dhs): 0.49 inch
Equivalent Diameter (Des): 0.49 inch
Number of Baffles (Nb): 4
Baffle Spacing (B): 9.00 inch
Bundle Cross-flow Area (As): 0.0750 ft^2
Pitch Length (PT): 0.62 inch
Clearance Length (C): 0.13 inch
Convectional Heat Transfer Coefficient (ho): 369 W/m^2.K
Reynold's Number (Res): 171
Nusselt Number (Nus): 35
Flow Type: Laminar
Friction Coefficient (fs): 0.67

31 | P a g e
 Tube Side
Inlet Temperature (Tt,in): 60 °C
Outlet Temperature (Tt,out): 61.24 °C
Mass Flow Rate (mt): 1.10 Kg/s
Fluid Velocity (Vt): 2.03 m/s
Pressure Drop (ΔPt): 15.9130 kPa
Outer Diameter (ODt): 0.50 inch
Inner Diameter (IDt): 0.33 inch
Hydraulic Diameter (Dht): 0.24 inch
Equivalent Diameter (Det): 0.33 inch
Number of Tubes (Nt): 10
Tube Passes (Np): 1
Tube Length (L): 3.00 feet
Heat Transfer Area (Ao): 3.9270 ft^2
Total Inner Surface Area (Ai): 2.5918 ft^2
Total x-section Area (At): 0.0059 ft^2
Pitch Ratio (PR): 1.25
Tube Layout = 90°
Convectional Heat Transfer Coefficient (hi): 13998 W/m^2.K
Reynold's Number for Heat Transfer (Ret): 36069
Reynold's Number for Pressure Drop (Ret,p): 26422
Nusselt Number (Nut): 180
Flow Type: Turbulent
Friction Coefficient (ft): 0.03

32 | P a g e
 FABRICATION METHOD
The entire fabrication process is divided into three main stages:

• Twisting of Copper Tubes

Due to the absence of specialized workshop facilities, the copper tubes were
manually twisted using basic tools such as a hammer and wrench. Each tube
underwent a marking process, identifying specific sections for twisting.
Subsequently, the tube was continuously rotated while being twisted.

• Shell Selection
Given that mild steel was chosen as the material for the shell, readily
available large diameter tubes of this material were procured from
workshops and hardware stores. The specific diameter of the shell was
determined through calculations, followed by the acquisition of a shell
meeting those specifications.

• Heat Exchanger Manufacturing and Assembly

With both the shell and tubes selected, the remaining manufacturing process
was carried out by a skilled manufacturer in the workshop. Comprehensive
specifications were provided to the manufacturer, and based on our
oversight, the welding and assembly of the heat exchanger were executed.

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 COSTING

Component Quantity(pcs) Cost (BDT)

½ inch dia. copper tube 10 4200
6-inch dia. Mild Steel 1 1000
shell
6-inch dia. Baffle sheets 3 baffles & 2 side plates 1000
and side plates
½ inch socket 4 200
½ inch tubing end cap 4 160
Manufacturing cost 3000
Total 9560

34 | P a g e
 PRESSURE TESTING
Regrettably, a notable incident occurred during the pressure testing phase in the
hydraulic laboratory, wherein it was discovered that one of the tubes exhibited a
leak. This unexpected development led to the unavailability of data from the
intended hydraulic test. Upon careful consideration, we hypothesize that the root
cause of this occurrence may be attributed to stress concentrations induced by the
twisting of the copper tube. While it is acknowledged that copper is renowned for
its commendable ductility, the incident prompts a reflection on our material
selection process. In hindsight, opting for a material possessing even greater
ductility could have been a prudent choice in order to effectively fulfill the outlined
objectives and mitigate potential challenges of this nature.

35 | P a g e
 FUTURE PLAN
We have the following plans to operate in future:

Exploring Alternative Tube Materials

• Investigate the viability of using different tube materials to improve overall
heat exchanger performance.
• Evaluate the thermal and mechanical properties of these materials to ensure
compatibility with the intended application.
• Assess the potential benefits in terms of heat transfer efficiency and
durability.

Optimizing Fluid Allocation

• Research strategies to optimize the allocation of fouling-prone fluids, such
as Engine Oil, to the tube side.
• Allocate less fouling-prone fluids, like water, to the shell side to reduce
fouling-related challenges.
• Explore the impact of this allocation strategy on heat exchanger performance
and fouling mitigation.

Increasing Shell Side Mass Flow Rate

• Investigate methods to increase the mass flow rate on the shell side of the
heat exchanger.
• Analyze the effects of higher mass flow rates on heat duty and thermal
performance.
• Consider the practical implications and limitations of implementing
increased shell side flow rates.

Minimizing Pump Consumption

• Conduct a comprehensive analysis of the system to identify opportunities for
reducing pump consumption.

36 | P a g e
• Explore strategies such as optimizing pump efficiency, adjusting flow
control mechanisms, or modifying system configurations.
• Evaluate the potential energy savings and environmental benefits associated
with reduced pump consumption.
• These planned initiatives collectively represent a commitment to continuous
improvement and the pursuit of enhanced performance and efficiency in heat
exchanger operations.

37 | P a g e
 CONCLUSIONS
The horizon for this innovative heat exchanger design holds immense promise.
With meticulous planning and expert craftsmanship, we can unlock its full
potential. Our hands-on exploration, rooted in the wealth of knowledge
accumulated over several semesters, has been a transformative journey for us as
budding engineers. This venture has not only honed our skills but also ignited a
spark of creativity and problem-solving. We eagerly anticipate the opportunity to
extend these insights into broader realms of engineering, paving the way for new
frontiers in innovation and design.

38 | P a g e
 REFERENCES
Yu, C., Zhang, H., Wang, Y., Zeng, M., & Gao, B. (2020). Numerical study on
turbulent heat transfer performance of twisted oval tube with different cross
sectioned wire coil. Case Studies in Thermal Engineering.
https://doi.org/10.1016/j.csite.2020.100759

39 | P a g e

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