Shell and Tube Heat Exchanger for Crude Oil Refinery

My team and I designed this shell and tube heat exchanger as part of our final project for our Design of Fluid and Thermal Systems class at the University of Miami. Though the design and calculations were a team effort, the CAD was exclusively my responsibility. It is a single pass shell and tube designed to be used in a crude oil refinery. The heat exchanger was designed to meet the following initial parameters: the crude oil entering the system must be cooled from 102°C to 65°C, while maintaining a constant oil mass flow rate of 80 kg/s, city water enters the heat exchanger's tube side at 20°C, the shell side (oil) pressure drop was limited to 160 kPa, and the tube side was limited to a pressure drop of 30 kPa. The resulting design was a shell and tube with a shell diameter of 37 inches, 596 tubes, 8 baffles, 118.11 inch tube length. The overall heat transfer coefficient of the heat exchanger was calculated to be about 1501 W/m²·K when clean. Using a fouling factor of 0.000176 W/m²·K, the overall heat transfer coefficient is about 964.23 W/m²·K. The shell side pumping power was calculated to be about 12.39 kW, and 432.01 W for the tube side. The shell side pressure drop came out to be 97.41 kPa, and 5.3 kPa for the tube side, both well below the preset limits of 160 kPa and 30 kPa. The overall cost of manufacturing this heat exchanger using carbon steel was estimated at around $22,717.40.