Overview
The Challenge
Designing process equipment like shell-and-tube heat exchangers requires complex, iterative thermodynamic calculations. Executing the LMTD (Log Mean Temperature Difference) and ε-NTU methods manually is time-consuming, rigid, and makes it difficult to visualize how slight geometric changes affect thermal performance.
The Solution
I engineered a Python-based simulation tool that completely automates these calculations. By inputting fluid types, flow rates, and physical geometry, the app instantly calculates heat transfer coefficients, pressure drops, and verifies if the design is thermodynamically feasible. It transforms static academic formulas into a dynamic, state-of-the-art decision-making dashboard.
Key Features
🌡️ Dynamic Thermal Analysis
Calculates overall U-values, LMTD, and effectiveness (ε-NTU) on the fly using Dittus-Boelter correlations.
📊 Interactive Visualizations
Generates real-time temperature profiles (for both parallel and counter-flow) and performance curves using Plotly.💧 Fluid Property Library
Built-in thermo-physical properties (density, viscosity, specific heat) for 5 common industrial fluids.⚙️ Hydraulic Sizing Check
Automatically estimates Darcy-Weisbach pressure drops and verifies if the available surface area meets the required design target.
Technical Implementation
The application is built with a strict separation of concerns. The backend "engine" (hx_engine.py) utilizes NumPy and SciPy to handle heavy mathematical lifting, energy balances, and fluid property retrieval.
The frontend (app.py) is powered by Streamlit, creating a reactive UI that updates instantly as users adjust parameters. Data visualization is handled by Plotly, providing clean, interactive graphs that visually map out the heat exchanger's internal behavior.
The Takeaway / Impact
Validating Engineering Design
Beyond just writing code, this project proves an ability to translate complex academic concepts into state-of-the-art simulation tools. It successfully mimics the exact calculations taught in advanced Mechanical Process Engineering programs, proving that theoretical physics can be packaged into user-friendly software that aids real-world engineering decisions.
Live Demo
Note: If the screen says "This app has gone to sleep due to inactivity." please click on restart app.