INSTITUTE OF TECHNOLOGY

DEPARTMENT OF MECHANICAL ENGINEERING

INTERNSHIP HOSTING COMPANY: DASHEN BREWERIES S.C
PROJECT TITILE: DESGIN OF HEAT RECOVERY SYSTEM FOR BOILER
BLOW DOWN

PREPARED BY:

NAME ID

1.

Advisor:Mr Lioul Fenta (Msc)

Internship duration:- first round july 6-august 30, 2021

Second round january 25-march19,2022

Date: march 22 2022

Gondar, Ethiopia
Declaration

i
List of table
Table 1 Recoverable heats from boiler blow down[10].................................................................................36
Table 2 absolute roughness of common pipes[13]..........................................................................................50
Table 3 pressure loss in pipe fittings and valves for turbulent flow[11]......................................................51
Table 4 thermal conductivities of some insulting material[11].....................................................................52
Table 5 Result....................................................................................................................................................53

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List of figure
Figure 1 Dashen Brewery Gondar Plant[10]....................................................................................................2
Figure 2 Organizational Structure[17].............................................................................................................4
Figure 3 Beer Production Process Flow............................................................................................................5
Figure 4 Mill star machine.................................................................................................................................7
Figure 5 Beer production process flow..............................................................................................................9
Figure 6 Fermentation and Bright Beer Tank..............................................................................................10
Figure 7 Uncaser...............................................................................................................................................11
Figure 8 Washer Machine................................................................................................................................12
Figure 9 Filler machine....................................................................................................................................13
Figure 10 Pasteurizer machine.........................................................................................................................14
Figure 11 Labeler machine...............................................................................................................................15
Figure 12 Caser..................................................................................................................................................16
Figure 13 Crate washer.....................................................................................................................................16
Figure 14 Process flow beer filling and packaging[10]..................................................................................17
Figure 15 Flow Diagram of Raw Water Treatment Plant[17]......................................................................18
Figure 16 Flow Diagram of CO2 Recovery Plant[17]....................................................................................19
Figure 17 Flow Diagram of Boiler Plant[18]..................................................................................................20
Figure 18 Approximate bottom blow down rate [11].....................................................................................35
Figure 19 heat recovery system integrated with the boiler system...............................................................39
Figure 20 chart for determining the vessel diameter[11]..............................................................................40
Figure 21 cylinder geometry Figure 22 cylinder..................................................................................41
Figure 23 stress conditions of the cylindrical vessel[11]................................................................................42
Figure 24 semi-spherical head geometry Figure 25 Head..........................................................................42
Figure 26 Leg Support...................................................................................................................................43
Figure 27 assemblies drawing of hot storage tank.........................................................................................44
Figure 28 LMTD correction factor for plate heat exchanger [11]................................................................46
Figure 29 single pass counter flow arrangement [12]....................................................................................47
Figure 30 pipe friction vs. Reynolds number and relative roughness[12]...................................................50

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Nomenclatures
BBT Bright Beer Tank
EBT Empty Bottle Inspection
FBI Full Bottle Inspection
CIP Cleaning In Place
ECU Electric Control Unit
CFD Computational Fluid Dynamics
PPM Part Per Million
LMTD Logarithmic Mean Temperature Difference
T hout Hot Outlet Temperature
T hin Hot Inlet Temperature
T cin Cold Inlet Temperature
T cout Cold Outlet Temperature
Re Reynold Number
Nu Nusselt Number
F Correction Factor
NTU Number Of Transfer Unit

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Acknowledgement
First, we wish to express our gratitude to GOD for giving us the strength to perform our responsibilities as an
intern and complete the report within the stipulated time. we are also grateful to my school advisor Mr. Lioul
Fenta(Msc), for his comments and suggestions while he came in the first round mentoring, Mr.Mathios
(advisor from the company), and for those whole hearted supervision during company attachment period. It
would have been very difficult to prepare this report up to this mark without their guidance. Moreover, we
would also like to express my gratitude to Dashen brewery share company operators who gave me good
advice, suggestions, inspiration and support. We must mention the wonderful working environment and group
commitment of this company that has enabled me to deal with a lot of things. Finally, thank my parents and
families for their endless love, encouragement and understanding they had shown during the whole time.

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Abstract
This paper describes about the design of blow down heat recovery system in Dashed Breweries S.C. at Gondar
plant of the brewery. Blow down water is the part of water that is purposely drained during the boiler
operation to limit the level of impurities in boiler water to an acceptable level. The aim of the present work is
to improve energy efficiency of steam boilers. So it is contains large quantity of heat energy. This aim has
been achieved through designed and manufactured of a heat exchanger consists of a plate unit to recover heat
from surface bottom blow down water and reducing indirect losses. It is concerned with the design procedures
that should be followed while designing boiler blow down heat recovery system. This project covers the
overall design procedures, limiting conditions, literature reviews, specifications, many standard tables and
charts are used as a reference to select a standard elements, detailed calculations and Considerations made
while designing. In this project we have explained about heat recovery system, bottom blow down and surface
blow down and how blow down has used for recover loss of heat, and how de-aerator and heat exchanger
works for recover heat loss.

This project also includes design of hot water and steam storage tank, Design of the heat exchanger, Design of
piping and insulation, cost analysis. Finally, discussion about result, conclusion about the project,
recommendation and reference also included.

Key Words: blow down, heat recovery system, limiting conditions, de-aerator, heat exchanger,

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Table Of Contents

Declaration............................................................................................................................................................i
List of table..........................................................................................................................................................ii
List of figure.......................................................................................................................................................iii
Nomenclature......................................................................................................................................................iv
Acknowledgement...............................................................................................................................................v
Abstract...............................................................................................................................................................vi
PART ONE..........................................................................................................................................................1
CHAPTER ONE..................................................................................................................................................1
1. Background of the company s.c....................................................................................................................1
1.1. Brief history of the company..................................................................................................................................1
1.2. Vision, Mission and Objective of the Company...................................................................................................3
1.3. Main products and services......................................................................................................................................3
1.4. Main Customer or End Users..................................................................................................................................3
1.5. Organizational Structure.........................................................................................................................................5
1.6. Beer Production Process Flow................................................................................................................................6
1.6.1. Raw Materials....................................................................................................................................6
1.6.2. Physical treatment of malt................................................................................................................7
1.6.3 Wort production (brew house)..........................................................................................................8
1.6.4. Beer production................................................................................................................................12
1.6.5.Beer filling and packing process of bottled beer............................................................................13
Figure 8 Washer Machine................................................................................................................................15
1.7.Utility room............................................................................................................................................................21
1.7.1.Raw Water Treatment Plant............................................................................................................21
1.7.2. CO2 Recovery plant.........................................................................................................................22
1.7.3.Cooling (NH3) Plant.........................................................................................................................23
1.7.4. Air Compressor................................................................................................................................24
1.7.5. Boiler plant (steam generation plant)............................................................................................24
1.7.6. Waste water treatment....................................................................................................................26
CHAPTER TWO...............................................................................................................................................27
2. The Overall Internship Experience.............................................................................................................27
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 2.1. Working Section of the Company..........................................................................................................................27
2.2. Work Task Executed..............................................................................................................................................28
2.3. Engineering Methods, Tools And Techniques.......................................................................................................28
2.3.1 .Methods.............................................................................................................................................28
2.3.2. Tools..................................................................................................................................................28
2.4. Major Challenges And Problems Identified...........................................................................................................29
2.4.1. Challenges Faced..............................................................................................................................29
2.4.2. Measures Taken To Overcome the Challenge...............................................................................29
CHAPTER THREE..........................................................................................................................................30
3.The Overall Benefits Gained From The Internship...................................................................................30
3.1. In Terms of Improving Theoretical Knowledge.....................................................................................................30
3.2. Upgrading myself with Kaizen principle...............................................................................................................30
3.3. In Terms of Practical Skills....................................................................................................................................30
3.4. In terms of improving industrial problem solving capability...............................................................................31
3.5. In Terms of Improving Team Playing Skills...........................................................................................................31
3.6. In Terms of Improving Leadership Skills..............................................................................................................31
3.7. In Terms of Understanding Work Ethics, Industrial psychology and related issues............................................32
3.8. In Terms of Improving Entrepreneurship Skills....................................................................................................32
3.9. In Terms of Improving Interpersonal Communication Skills.................................................................................33
CHAPTER FOUR.............................................................................................................................................35
4. Conclusion And Recommendation.............................................................................................................35
4.1. Conclusion.............................................................................................................................................................35
4.2. Recommendation...................................................................................................................................................35
Part two..............................................................................................................................................................36
CHAPTER ONE................................................................................................................................................36
1. Introduction...................................................................................................................................................36
1.1. project summery....................................................................................................................................................38
1.2. Problem Statement...............................................................................................................................................39
1.3. Objective...............................................................................................................................................................39
1.3.1. Main objective..................................................................................................................................39
1.3.2. Specific objectives............................................................................................................................39
1.4. Limitation of the project........................................................................................................................................40
CHAPTER TWO...............................................................................................................................................40
2. Literature Review..........................................................................................................................................40
2.1. Methodology For Design Of Boiler Heat Recovery System..................................................................................42
2.2. Selection of material...................................................................................................................................42

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 2.2.1. Corrosion resistance........................................................................................................................42
2.2.2. Mechanical properties.....................................................................................................................43
2.2.3. Electric & Magnetic properties......................................................................................................43
2.2.4. Recycling...........................................................................................................................................43
2.3. Selection of Types of joint....................................................................................................................................43
CHAPTER THREE..........................................................................................................................................44
3. DETAIL DESIGN AND ANALYSIS..........................................................................................................44
3.1. Collected data or specifications............................................................................................................................44
3.2. Economic Feasibility..............................................................................................................................................44
3.2.1. Continuous Blow Down Rate..........................................................................................................44
3.2.2. Bottom blow down rate...................................................................................................................45
3.2.3. Cost saving........................................................................................................................................46
3.3. Heat Recovery System..........................................................................................................................................48
3.4. Hot Water Storage Tank Design............................................................................................................................51
3.5. Design of Shell.......................................................................................................................................................51
3.5.1 Stress Analysis for the shell..............................................................................................................53
3.6. Design of Head......................................................................................................................................................54
3.7. Design of support...................................................................................................................................................55
3.7.1. Stress Analysis for Leg Support.....................................................................................................56
3.8. Heat Exchanger Design.........................................................................................................................................57
3.9. Pressure drop.........................................................................................................................................................62
3.10. Servo Meter Selection.........................................................................................................................................63
3.11. Piping design.......................................................................................................................................................63
Optimum pipe diameter............................................................................................................................63
Pressure drop through the pipeline..........................................................................................................63
Miscellaneous pressure losses...................................................................................................................65
3.11.1. Stresses in Pipes..............................................................................................................................66
3.12. Insulation design..................................................................................................................................................67
CHAPTER FOUR.............................................................................................................................................68
4. RESULT AND DISCUSSION......................................................................................................................68
4.1 RESULT.................................................................................................................................................................68
4.2. DISCUSSION........................................................................................................................................................69
CHAPTER FIVE...............................................................................................................................................69
5. CONCLUSION AND RECOMMENDATION..........................................................................................69
5.1. CONCLUSION.....................................................................................................................................................69
5.2. RECOMMENDATION.........................................................................................................................................70

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x
PART ONE

CHAPTER ONE
1. Background of the company s.c
1.1. Brief history of the company
Dashen's modern plant, occupying an area of 8.5 hectors, was completed with an initial capital investment of
over 340 million Birr. The Brewery is located in the historical town Gondar which is annually visited by more
than 95,000 tourists. It's named after Mount Dashen, Ethiopia's highest mountain elevation 4523 meters), and
a home to rare endemic fauna and flora and renewed for its breath taking scenery. The principal aim of Dashen
Brewery is meeting the customer requirements for quality beer and to offer customers more choice in the
market without affecting the environment .Thus, the brewery is highly committed to waste reduction, waste
management and satisfying customer need and expectations. Dashen brewery utilizes state of the arts
technology and has a highly qualified professional work force that will enable it to complete on the export
market with the leading international beer producing and marketing companies. Dashen Brewery has an initial
annual total capacity of 500,000 hectoliters (151 million bottles ) current production output stand at 300,000
hectoliters (91 million bottles ).Despite its young age, Dashen brewery has already been a beer tycoon and a
pioneer in customer satisfaction, which is confirmed by being awarded two internationally, recognized
certifications, ISO9001 and ISO 14001

As a result of relentless effort of its professionals, its high-tech technology and appropriate strategy designed
to penetrate the seemingly congested local market, the brewery is now in a position where its supply could not
meet the demand created for its products .This has therefore put the brewery in the forefront of the local
market even at its infant stage. Hence, the work to expand the Brewery to three fold of its actual current
capacity has already begun. The new capacity after expansion, assumed to be finalized in the coming August,
will put the brewery at number one position with respect to both quantity and quality. The brewery has above
600 employees; a figure anticipated to increase within the next 6 months as the company steadily expands its
market share and plant capacity to 750,000 hectoliters (or 225,225,225Bottles).In line with this, modern
technology diffusion and vigorous human resource capacity development work is under taken at all levels. As
to the raw materials the brewery uses the most suitable water; two raw spring barley malt, carefully selected
yeast and hops only. The Brewery is currently undertaking projects of malt factory to supply the Brewery and
other Brewery's with a sustainable supply of quality malt produced in the unique two-raw barely grown in the
high lands of the region. The project aims to benefit the farmers of the area by integrating them as suppliers of

1
the Barely for the factory Dashen Brewery is taking in various activities as part of its social responsibility to
the society. The Brewery has been working with youth associations and clubs in the fight against HIV/AIDS.
Helping street children, creating self help job opportunities etc.
Dashen brewery is the only and first ISO 9001 and ISO 14001 certified company in Ethiopia which are
passports for the global market. The Brewery's ISO 9001 Quality Management system has won customer
confidence that the brewery is supplying products of desired quality with its internationally recognized system
.Dashen's ISO 14001Environmental Management System will enable the company to formulate a policy and
objectives by taking in to account regulatory requirements and information on activities with significant
environmental impacts. Dashen brewery utilizes state of the arts technology and highly qualified experts that
will enable it into compete on the export market with the leading international beer producing and marketing
companies. The brewer has modern technology diffusion vigorous human resource capacity development
work is under taken at all levels. The brewery uses the most suitable water for brewing quality beer; two row
springs, barley, malt, yeast and hops nothing else added.

Figure 1 Dashen Brewery Gondar Plant[10]

1.2. Vision, Mission and Objective of the Company

Vision
 To make dashen the central value for quality beer celebrities

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  To Building the brands that people love prefer to drink.
Mission
 It is an endowment (gift) fund established to contribute for the development of Amhara region by
producing and selling costumer proffered or contribute quality beer at competitive price and generate
responsibility
 To be best Ethiopian beer lead drinks company with sustained revenue growth and consistently
improving returns on invested capital.
 Employees of the brewery have a fair commitment ownership feeling or especially the technical team
their commitment is increasing. Generally employees in production quality maintenance department
are highly committed energetic with fair a composing
Objective of the company
 To support the socio-economic development of the Amhara Region in particular and the overall
development wellbeing of the country in general
 To give value for the eco-environment friendly manner.
 To involve in export market.
 To reduce productions loss.
 To reduce breakage.
 To reduce water consumption.
 To reduce power consumption.
 To ensure product consistency at the required level.

1.3. Main products and services

The main products of Dashen brewery are:
 Dashen beer,
1.4. Main Customer or End Users
The end users/customers are every person aged above 18 years old. There is no any limit or boundary in order
to be a customer for Dashen beer. The products are distributed across the country in four regions and three
warehouses.
The regions are:
 Region 1: covers Amhara, Benishangul and Afar region.

 Region 2: covers the whole Tigray region.

 Region 3: covers central and western part of Ethiopia.

 Region 4: covers east and south parts of Ethiopia.

The three ware houses thus are, Gondar, Waldia and Addis Ababa

3
Dashen brewery exports its products to the following foreign countries:
 California, Chicago in America
 Australia
 Israel
 South Sudan

4
1.5. Organizational Structure

Figure 1 Organizational Structure[17]

1.6. Beer Production Process Flow

1.6.1. Raw Materials
The main raw materials those Dashen brewery uses to produce beer are malt, yeast, hops, Water & chemicals
such as CaSO4, H3PO4, CaCl2 and caramel.
The production of beer is tied to three consecutive biochemical processes.
 The formation of enzymes in germinating grains
 The breakdown of starch to sugar by enzymes
 The fermentation of sugar to alcohol and CO2.
5
 Figure 2 Beer Production Process Flow

1.6.2. Physical treatment of malt

The malt is imported from Belgium and in addition to this Gondar malt factory also supplies malt to the
company. This malt is imported without purification. The impurities are metal, stone, other gain straw and
other objects, so to need purifications:
Intake Hooper: The purpose of this is to discharge the malt into pre cleaner by bucket conveyors
(elevators)

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Pre cleaner: Pre clean ear is installed with inclination, because easily remove straw, sack binders, piece
of wood etc.

Dry destoner: The pre cleaned malt is intake to the destoner the main purpose of this they are used to
separate granular material according to specific weights, Less than malt size , Equal to malt size and Greater
than malt size like coffee and other grain.

Pipe magnet -Magnet devices are built into operate near the start of processing, so that iron parts flowing
with the product can not cause any damage. Simply remove metal part from the malt.

Mechanical weigher-Pure malt is before it release into malt mill weigher records the weigher release 50
kg in one time they it moves by chain convey to malt mill.

Cyclones: A cyclone consists of a cylindrical upper part into which air is blow tangentially the cyclone
tappers conically down ward. The dust particle are forced outward by centrifugal force slide down ward and
are discharge through in out let hopper and packed in to sacks.
1.6.3 Wort production (brew house)
Mill star -This machine contents of four parts
 Hooper, Pure weigher malt is feed in to hoper

 Stepping

 Malt steeping before filling pure malt step with hot water a temperature of 58oc b/c of do not produce
powder

 Crushing zone The stepping malt enters into the crushing roller by control of feed roller.
The purpose of feed roller is to control the entering steeping malt them the stepping malt is crushing with two
rollers due to roller. And also entering mashing water to remove the crushing malt at two rollers.

7
Figure 3 Mill star machine

 Mashing vessel
The mash vessels are:
 Mash kettle-decoction
 Mash tun kettle infusion process
Dashen uses mash tun kettle Mash tun kettle
 To digest the wort with continuous striling before going to lauter ton tank

 To change starch into simple sugar.

 Lauter tun
The process of the mash consists of a water mixture of dissolved and un-dissolved substance the aqueous
solution of the extract is called wort and the insoluble part is called spent grain. The liquid part going to pre
run tank and the spent grain is removed by spent grain removal.

 Wort pre run tank

 The purpose of this is to collect the liquid part of the wort coming from lauter tun the flow is
requisitely by temperature valve

8
  And also addition of carmine is takes from here to change the color of the beer.
 Wort kettle
Wort kettle is an optimum tank for boiling wort which simple design a variety of combination option like
external boil and hoper adding the external boil wort 1-2 hour about 98oc in this tank hopes are added
according to the brewery specification.
 There are two different hopes added on the wort kettle these are For bitterness, for color, Extract
flavor and aroma compound from hope, the main purpose of wort boil is to remove water.
 Once the wort boiling process is complete the wort is pumped in to the whirl pool
 At wort kettle have different valves
Whirl pool
 The enclosed cylindrical vessel with a flat base and 2% inclination towards the outlet of simple
design the whirl pool is an optimum vessel for separating the wort from the hot trub. In this
tank wort which is for beer purpose is produce as the main output the other part which is
unnecessary one is extract as trub to the trub tank near to the whirl pool then the trub store and
move to lauter tank.
Wort cooling
 Wort which can be produced in the whirl pool is very hot with high temperature this need to
minimize to the lower temperature as it needed this is performed using plate heat exchanger
which is ready for this purpose inside the brow house heat exchange minimize the hot wort
temperature from 95 0C to11 0C.

9
 Spent grain

Malt Milling star Mashing Lauter tun

Wort cooling and Whirl pool Wort kettle Wort pre run tank
yeast addition

Fermentation Filtration
1.
tank plant

Figure 4 Beer production process flow

1.6.4. Beer production

 Yeast propagation
There are three distinct stage in pure yeast propagation.
 Isolation of suitable yeast cell

 Multiplication of the yeast in the laboratory

 Yeast multiplication in the plant until an amount sufficient pitching is obtained.

 Fermentation tank
 During fermentation the sugar in the wort is fermented in to ethanol and carbon dioxide by
yeast sugars are fermented in accordance with Gay-Lussac equation.
C 6 H 12 O6 2C 2 H 5OH+2CO 2
 In dashen brewery fermentation takes 19-21 days in this day the wort is cooling by glycol with
60 0C to rotate the fermentation tank.
 Fermentation tanks are cylindrical council vessel which is built with cylindrical upper part and
conical shaped lower part
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  Beer filtration tanks
Filtration is separation process in which the yeast cell and other turbidity cause in material still present in the
beer are removed from the beer. The purpose of filtration is to make beer so stable that no visible changes
occur for a long time and so these beers looks the same as when it was made.
Filter aid are powdery substance diatom ate which are used in the brewery for the filtration of beer then
filtered beer transferred to bright beer tank.
 Bright beer tank (BBT)
The only purpose is to store the filtered beer dashen brewery has 6 BBT, then filtered beer transferred to bottle
filler or draught filler.

Figure 5 Fermentation and Bright Beer Tank

1.6.5.Beer filling and packing process of bottled beer

 Un caser (unloading)
During this process of this the bottle and the create are separated by using pneumatic valve the equipment has
an efficiency to separate the bottle from the crate at a time.

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Figure 6 Uncaser

 Bottle washer
The shelf life of depends very greatly on the stage of the cleaned bottle empty bottles are returns solid to very
different extent from customers but all bottles, even the very dirty ones must be cleaned to hygienically perfect
condition.
In all case there are two tasks to be accomplished
 The bottle must be cleaned mechanically

 All beer spoilage micro organisms must be removed and killed

The mechanical or optical cleaning effect is regarded as achieved when no visible soiling can be detected in or
on the bottle. Mechanical cleaning is considered to have been achieving if the bottles are covered by
continuous film of water.

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 Figure 7 Washer Machine
 Visual inspection
Visual inspector is used to inspect of all cleaned bottles from out bottle washer;
 Empty bottle inspection
To reject this machine like
 Foreign bottles, Faulty bottles and Contaminated bottles

And to detect

 Caustic detection , Side wall inspection, Lateral neck finish inspect and

 Bottle height detection

 Filler machine
Bottle filling machines are always built as rotating machines with up to 120 filling valueDuring rotation of
the filler the bottle are

 Pressed against the filling element

 Evacuated and counter pressurized once or twice

 Filled
 The filling height in them is corrected
 The pressure is released and
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  The bottle are lowered again and mixed away.

Figure 8 Filler machine

 Crowner cork

The crown cork pass and magnetic conveyor band a slide or other conveying device into the storage hopper of
the bottle closer and there is brought in to the correct orientation by a sorting devices.
The crown cork which may be turned 1800 from the correct positioned can thereby is brought in to the correct
position by a simple guide device. The closing element it is lowered by the curved track on to the bottle until
the crowner corks rests on the bottle mouth then the springs forces the closure on to the bottle and the closing
comes forces it down

 Pasteurizer
 No viable micro organism is to treat at the last possible movement that is the beer is treated
various water circulation path in order to utilize recovered heat. It takes about an hour to pass
through.

 There are ten sections in which one bottle stays the pasteurization unit 6 minutes.

14
Figure 9 Pasteurizer machine

 Labeler
The main function of labeler is labeling on neck and body of the beer bottle. The appearance of the bottle is
extremely depending on the quality of the labeling to be able to do this label paper must have the following
properties are contained
 Amount (volume)

 Expired date

 Production data

 Ingredient(food grades)

Generally for labeling process glue and air are the two important materials coating of the label.

15
Figure 10 Labeler machine

 Full bottle inspection (FBI)

The full bottle inspector defects;
Neck label, Body label, Missed label, proper closing of crown cork, under fill and overfill.
The presence and arrangement of the labels are checked by using photo electric sensor if there is a problem or
error it sends a signal to a rejection.

 Caser (loading)
It is pneumatic operated machine which can put down the bottle with in the crate.
Note: caser and UN caser machine.
The bottle in a crate are fitted from the crate by a gripper head and set down at a predetermined position. The
sequences of operation are performed continuously.

16
Figure 11 Caser

 Crate washer
The crate can become dirty during transportation and in store after emptying they pass through a create washer
and turner are stacked in crate store until used after a filler.

Figure 12 Crate washer

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 Empty bottles in Unpacked Bottle washer Visual inspection
Empty crate washer
crate from market

Bottle labeler Pasteurization of Bottle filler machine Empty bottle

machine filled bottle inspection machine
(EBI)

Bright beer tank

(BBT)

Full bottle inspection packer Palletizes

Full product store

Figure 13 Process flow beer filling and packaging[10]

1.7.Utility room
It is the back bone of the company because it is the source of steam, process water, glycol and carbon dioxide
purification those have significant impact on production.

1.7.1.Raw Water Treatment Plant

This plant treats and classifies raw water, which finally categorized as processed water and service water. The
first process starts with the water that comes from the raw water station, and then it enters into the water
treatment plant; and this process, in fact, takes place first, it enters to the sand filter tank by using pumps. The
sand filter tank absorbs the impurities as well as the dust particles. After that, the water is relatively become
clear and added chlorine on the water to make it clear completely, then it goes through the pressurized tank by
using four supply pumps. After it pressurized, the water is going to be pumped and distributed into two
branches that are finally classified to processed and service water.

18
Processed water is used to prepare the beer, so that it must be cleared from chemicals (chlorine), and to
remove chlorine, which passes through the activated carbon filter tank, the carbon filter tank absorbs chlorine
and then the water is free from any chemicals. Therefore, finally it goes to the fermentation process. The
service water is used for steam and other services, as it is used for cleaning, drinking, and showering.

Figure 14 Flow Diagram of Raw Water Treatment Plant[17]

1.7.2. CO2 Recovery plant

The dissolved co2 content of beer is an important facility parameter particularly for the production of good
live line in beer

Components of co2 recovery plant:

 Compressor: it is piston type. In the first stage air enters and compressed at approximately 2bar at
second stage compressed at 15bar.

 Heat Exchanger: it is a plate type heat exchanger.

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  CO2 Balloon (storage): It controls carbon dioxide passage.

 Scrubber: carbon dioxide from fermentation showered by water

 CO2 Condenser: Co2 cooled by ammonia (NH3).

 Ammonia compressor

 Dehydrator: It absorbs the moisture.

 Carbon filter: It removes odor and impurities.

 CO2 Condenser: It is a shell and tube type heat exchanger, in which co2 is on tube side and NH3 is
on the shell side.
At a pressure of approximately 18 bars and a temperature of -24oc, the co2 is condensed. The condensed co2
is flowing by gravity to storage tank. Water scrubber showers the unpurified CO2 from fermentation. Before
the CO2, gas enters into CO2 balloon, the moisture is removed by water lock and dehydrator. For this, there is
heat exchanger to reduce the temperature. This is how the process takes place:

Figure 15 Flow Diagram of CO2 Recovery Plant[17]

1.7.3.Cooling (NH3) Plant

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This plant is made to cooling glycol. The plant is working at the temperature of -350c. The plant is designed
for cooling of 230m3 propylene glycol per hour from -0.40c to -40c. This is taking place at evaporating
temperature at -80c. The refrigeration process is taking place in a plant heat exchanger. From the receiver, at a
temperature of approximately 330c, liquid is conducted through a drift filter type retaining any impurities.
After the drift filter, the pressure in the liquid is throttled from 13 bars to 1.3 bars (330c to -80c).

Glycol Tank: The glycol tank is divided in two parts. The cold side (-40c) and warm side (-0.40c) from the
cold side, two pumps pump 208m 3/h glycol to the process area. In the return line from pressure control valve
is mounted. This valve ensures a constant pressure in the system independent of the consumers. This gives
constant flow from supply pumps. The glycol returns to the warm side of the tank. From the warm side of the
tank, 230m3/h is circulated by two pumps through the glycol cooler, which the hot glycol comes from the
manufacturing class at -0.40c. Thus, it exchanges heat with ammonia (NH3), which the ammonia comes from
its tank. The heat exchanger is a plate type. After heat exchange, the temperature of glycol is -40c and it goes
back to cold glycol tank, and then it returns the glycol to the cold side of the tank. Between tank and pump, a
pressure expansion vessel is mounted to absorb the pressure fluctuation of the plant. Furthermore, a safety
valve is mounted to protect against super pressure. At the outlet of the glycol cooler, a differential pressure
switch is mounted as frost protection.

1.7.4. Air Compressor

All pneumatic systems are activated by air, and the sources are from atmospheric air. The air, which sucks
from external environment, is compressed before it stored to clean impurities.

1.7.5. Boiler plant (steam generation plant)

In this utility section steam generation is the main (primary) time of the plant which is used for different
equipment CIP (cleaning in place) in whole part of the process plant and also to pasteurization beer and here is
they in which how steam will be formed in the boiler.

21
Figure 16 Flow Diagram of Boiler Plant[18]

The service water comes from in the raw water treatment section, and this water will be softened the soft water
and then that will be sent into the carbon filter to de-mineralize (remove CL) the water. De-mineralize means
free of any material substances the soft water feed into feeder tank (pre heater). Thus, that is rinsed by super
steam reservoir of the soft water up to 1030c and at this stage 90% of O2 removed from the tank by the steam,
and 10% of O2 removed by adding Amersite (Na2SO3) in the heater tank of water for sucking in order to
prevent the formation of corrosion. The reason of avoiding O2 in the water is to prevent oxidation.

The main energy source of the boiler is furnace oil. The boiler consists of horizontal well-insulated sheet steel
cylinder at one side of the boiler, and fire-tube is at the front end. The burner is installed by means of this and
the air/oil mixture is burned in large flame in the boiler. Then, steam moves from boiler to steam reservoir
(steam distributer cylinder). The main aim of this cylinder is to distribute the steam to the required place for
the required amount.

22
1.7.6. Waste water treatment
This waste water is dangers for environment, so that to need treatment like Mechanical treatment: - have a
great chamber to remove metal greater than 20mm and also have semi-submersible pump to mix the waste
water do not baking. Chemical treatment:- to add sulfuric acid to control the PH value Biological
treatment:- to facilitate aerobic system to enter O2 The finally produced fertile soil and water for purpose of
plants.

23
 CHAPTER TWO

2. The Overall Internship Experience

Internship is one method of making opportunity for undergraduate students potentially valuable and explores
general career avenues as well as specific companies. Such arrangement can provide us with valuable work
experience and an opportunity to line up job before graduation, in addition to securing good work experience.
Internship programs are also potentially valuable to company. Unfortunately, some companies continue to
regard interns as a little more than free source of labor to catch up on filling and other tedious office work.
However, many business owners and managers realize the internship programs can provide them with an early
opportunity to gauge the talents of a new generation of workers and, in many cases, sell themselves as a
quality place for students to begin their careers after they graduated.
While we participate in this internship, we expect that only practical and theoretical knowledge will be gained
in the internship but after completing of the internship, we were able to realize that we get so many benefits
some of them are described above from intern perspective view and company perspective view. The major
benefits that we get from the internship are classified and stated as below briefly.

2.1. Working Section of the Company

Since we are mechanical engineering student, we directly involved into the maintenance and production
activities. We were always there wherever maintenance of production equipment’s and machineries is being
done. But mainly we were allocated to the following areas
 Packaging and bottling

 Workshop and garage

 Utility

2.2. Work Task Executed

The major tasks that we were involved are

 Design of boiler blow down heat recovery system design

 Boiler efficiency test

 Conveyer maintenance

 Labeler disassembly, cleaning , servicing and assembly

 Filler overhauling

 Caser and un caser overhauling

24
  boiler plant overhauling including boiler burner disassembly servicing and assembly, furnace oil
pump maintenance, blow down discharge maintenance, boiler fire tube cleaning

 co2 recovery plant overhauling including ammonia condenser decaling, co2 intercooler and after
cooler decaling, activated carbon replacement,co2 evaporator replacement, micro cooler decaling,

 cooling plant overhauling including evaporative condenser decaling

2.3. Engineering Methods, Tools And Techniques

We have tried to apply the methods that I acquire and tools that are available to the subject as well as the
techniques I can discover to be applied. Among them
2.3.1 .Methods
 problem solving

 data collection

 data analyzing

 maintenance

2.3.2. Tools
 extractor to extract bearings, gears

 welding machines

 grinders

 pipe wrench

 Allen key set

2.4. Major Challenges And Problems Identified

Since we were theoretical students, it was difficult for us to know even the mechanical equipment’s. We were
confused to understand the working principles of machines when they are working because we were not
properly introduced to the practical world. The other difficulty was there some areas that are not allowed for
students to enter. In order to be familiar with the mechanical devices, we first tried to observe them when they
are not working by asking anyone in the room about them repeatedly to enable us to know the internal
deriving mechanisms

2.4.1. Challenges Faced

The first challenge was the perspectives of the management staffs about the internship students and because of
this they didn’t allowed us to enter in to the filling and packaging section during weekly maintenance day for
25
the first three weeks. The other challenge was there were many intern students in the company and it was
difficult to get a particular task for an individual

2.4.2. Measures Taken To Overcome the Challenge

In order overcome the challenge we follow the following measures and finally we develop trust and a good
relationship with workers and management staffs.
 By working hardly beyond the specified working time.

 By doing every task even if it is not concerned me.

 Giving positive suggestion and friendly commenting the tasks.

26
 CHAPTER THREE

3.The Overall Benefits Gained From The Internship

3.1. In Terms of Improving Theoretical Knowledge

we have been learning and upgrading our theoretical knowledge. The internship period allowed us to gather
real time activity of industrial systems. So the internship period was our crucial moment to get theoretical
knowledge from the company and upgrading our self with the working environment. Many of this knowledge
were gathered from the operators and maintainer of the company office work.

3.2. Upgrading myself with Kaizen principle

Now a day’s Ethiopian industries uses this principle in order to continuously improve their products.
Therefore, understanding of this principle is crucial for our future carrier.
Kaizen is a Japanese philosophy for process improvement that can be traced to the meaning of the Japanese
words ‘Kai’ and ‘Zen’, which translate roughly into ‘to break apart and investigate’ and ‘to improve upon the
existing situation.
The five S’s of Kaizen principle are:
 Sort

 Set-in-order

 Standardize

 Sustain and

 Shine

3.3. In Terms of Practical Skills

One of the best opportunities that we had in our stay at dashen breweries was working with international
recognized company engineers. This opportunity helped us a lot to gain practical skills. In addition to this we
also get different practical skills from company employees.
Every activity of assembling and disassembling of any machine is depending on the skill of understanding of
the blueprints and drawings. Therefore, we learnt this skill by asking and working with these foreign machine
specialists.
3.4. In terms of improving industrial problem solving capability
As we mentioned in the previous topic, we gained a lot of benefits that helps us to improve our capability of
solving industrial problems. Now days many industries like food and beverage factories like dashen brewery
uses root cause analysis to find out the source of the problem to effectively find the solution of the problem.
27
Root cause analysis is a structured facilitated team process to identify root causes of an event that resulted in
an undesired outcome and develop corrective actions. The RCA process provides you with a way to identify
breakdowns in processes and systems that contributed to the event and how to prevent future events. The
purpose of an RCA is to find out what happened, why it happened, and determine what changes need to be
made. It can be an early step in a PIP, helping to identify what needs to be changed to improve performance.
3.5. In Terms of Improving Team Playing Skills
Team playing skills are one of the most important requirements for the proper working of procedures in any
company regardless of its size and/or service it provides. Therefore, team play skill has the potential to help
me improve skills like:
 To increase self confidence

 Easily control the environment

 Easily solve problems

 To shared knowledge’s

 To give fast decision making

 To interpret the problems and solve the problems

 Giving respect for others

3.6. In Terms of Improving Leadership Skills

This internship period was a time of improving our leadership skills. We were trying to develop our leadership
skills by giving comments, sharing ideas and participating in the works. Specially, on occasion we were given
the chance during overhauling maintenance, we were expected to pass decisions, to organize the workers (like
we tried to coordinate the workers to listen and do what the foreign experts order them.), listen and give
opinion for the workers questions and interest.
In general a leader is a person who has strong principles, courage, dedication of a clear vision, and decision-
making ability. Therefore, in this internship program we were able to develop important leadership skills that
play the following roles to us:
 Creating and managing the vision
 Making good decision

 Communicating effective

 Using appropriate style and power

 Leading change

 Motivating and developing others

28
  Resolving conflicts and issues

 Creating positive culture and climate

 Conducting meaningful evaluation

3.7. In Terms of Understanding Work Ethics, Industrial psychology and related issues

Work ethics is the basic behavior one should have in doing his job and fulfilling responsibility. This involves
attitude, behavior, respect, communication and interaction; how one gets along with others. If one fails to
respect the work ethics he will be punished according to the rule of the company. The company has its own
rule and ethics regulation.

In four months stay in the company, we (the students) were expected to sign a attendance, so we are expected
to enter and leave at the specified time only. In addition to this we, the students, were supposed to be
transparent and accountable for the tasks we were given. For instance, when the utility Engineer gave us
assignments, he expects our transparency and accountability for what we had done.

Strong work ethics is a key to be productive and industrious in any given profession. So that in any working
environment, we must fulfill the following expectations and behaviors:
 respect the rules and regulation of the company

 Accountability and responsibility

 Be punctual, motivated, confidant

 Give smooth relation to the partners

 Respect for all workers

3.8. In Terms of Improving Entrepreneurship Skills

The word entrepreneurship has got different meanings as used by scholars of different professions such as
psychology, sociology, economics, and others. Generally, entrepreneurship process is the composition of five
basic things.
1) Ability to see work opportunities and recognizing their type.

2) Ability to change these work opportunities to business

3) Persistence to continue in the business

4) Ability to work in strategic way

5) Ability to understand & accept if there is possibility of loss or any problem

29
Entrepreneurship success depends on personal behavior (traits), skill & profession. Among entrepreneur’s traits
(characters):-
 Self-confidence and optimism

 Able to take calculated risks

 Positive response to challenges

 Flexibility and ability to adopt a new technologies

 Knowledge of market

 Independent minded

 Seeking for new information

In every aspect of life especially in business, there are five effective principles:

 Be on time, first come, first served

 Be cooperative and work together with others
 Plan by considering which to be first
 Consider common goal
 Listen others and learn from others

3.9. In Terms of Improving Interpersonal Communication Skills

In terms of improving our interpersonal communication skills this internship period was very crucial moment
for us. This occasion gave us the chance to know different people both in the work place and outside. We
weren’t that much shy and it wasn’t very difficult for us to communicate with others. The internship gave us a
lot of opportunities to communicate with many people who were participating in the work such as the foreign
machine experts, company employees (like the engineers and the foramen and soon).
In addition to these we had a good communication with our friends from different campus and other
universities too. Those students, who were participating in the internship program, were from Bahir Dar
University, Adama University, Addis Ababa University, and Hawassa University, since these students have
their own life experience, this occasion was a good time for cultural exchange and experience sharing

30
 CHAPTER FOUR

4. Conclusion And Recommendation

4.1. Conclusion
Generally, this internship is good program of transmitting knowledge, improving practical skill, upgrading
theoretical knowledge, improving interpersonal communication skill, improving team playing skills,
improving leadership skills, understanding about work ethics related issue and improving our entrepreneurship
skills and also we learned a lot of very related things about maintenance in broad and we can connect our self
with higher technology of the world besides to our theoretical knowledge. And finally, this internship is the
best way to get knowledge’s in multi direction therefore this program should continue in the next generation.

31
4.2. Recommendation
We have a lot of recommendation to the company but we want to give more emphasis on the development of
research and design team. The company should have research and design team to improve the company
production performance and other related tasks by assessing the problem associated with the work flow.

Dashen Brewery has got a problem of how to manage students coming for internship. The company must have
a well-organized document for coming internship students how to work, where to work, when to work, what
to work and who will be the responsible to advise them. Finally, this Dashen brewery S.C. has shortage of like
internet access or haven’t computer accesses and haven’t reference books for improving knowledge’s of the
staff.

32
Part two
CHAPTER ONE
1. Introduction
Even efficient enough the water treatment plant is, some impurities grouped as suspended particles and
dissolved solids feed into a boiler with the feed water. When the water boils off the impurities remain in the
boiler since steam is distilled water. As the boiler continuous its operation, the amount of impurities remains
in the boiler increases. The suspended particles also called sludge settle on the heat transferring surface
forming scale which will reduce the heat transferring efficiency. The dissolved solids carried over with the
steam to the downstream pipes thereby erode them and reduce the thermal conductivity of steam. To avoid this
trouble by controlling the amount of sludge and total dissolved solids (TDS), the boiler need to be blown
down periodically and continuously.

All steam boilers must blow down to reduce the amount of TDS in the boiler water. Blow down However,
along with the solids, boiler chemicals and thermal energy is lost; blow down heat recovery systems cannot
recover the chemicals, but they do recover up to 90% of the heat energy that would otherwise be lost down the
drain. There covered heat is use to pre-heat boiler make-up water before it enters the de-aerator, and for low
pressure steam to heat water inside the de-aerator, which reduces the cost to run the de-aerator and improves
overall boiler efficiency. Reducing the temperature of the blow down before it reaches the sewer drain is a
typical Code requirement. Therefore, a heat recovery system also eliminates the need to dilute blow down with
cold water before it enters the sewer. Blow down heat recovery systems offer a fairly rapid payback,
depending on blow down volume. Several boilers can be connected to a single heat recovery unit, reducing
capital costs.
Energy efficiency has become an important feature of process industry with rising cost of energy, and the
more stringent environmental regulations being implemented worldwide; today the most prominent targets of
modern technology to improve the efficiency of energy technology in industrial processes particular industries
that generate their own steam need to optimize their energy generation and use by making all the measures are
taken to reduce energy loss.[9] Steam boiler is one of the largest equipment, which consumes energy
greatly.The boiler efficiency is dependent upon decreasing of various indirect losses of a boiler. Thus the
quantity of energy entering the boiler by consumption of fuel can be maximum utilized for generation of
steam and the cost of steam can be reduced ultimately through utilization of several methods to increase
industrial boiler efficiency that can be implemented relatively easily by minimizing the indirect losses.[7] The
33
main areas for improvement of result from “reduction in blow down water and blow down heat
recovery”.Boiler blow down water is water wasted from the steam boiler while the boiler is running to avoid
concentration of impurities during continuing evaporation of steam.[8] Even efficient enough the water
treatment plant is, some impurities grouped as suspended particles and dissolved solids feed into a boiler with
the feed water. When the water boils off the impurities remain in the boiler since steam is distilled water. As
the boiler continuous its operation, the amount of impurities remains in the boiler increases. The suspended
particles also called sludge settle on the heat-transferring surface forming scale, which will reduce the heat
transferring efficiency. The dissolved solids carried over with the steam to the downstream pipes thereby
erode them and reduce the thermal conductivity of steam. To avoid this trouble by controlling the amount of
sludge and total dissolved solids (TDS), the boiler need to be blown down periodically and continuously.

Blow down is a simple fact of boiler operation, which occurs when water is removed from the steam boiler
while it is operating. Since there are two groups of impurities, the process of blowing down happens in two
ways at two boiler positions. The suspended particles are ejected periodically at the bottom of the boiler thus
process is called bottom or periodic blow down and the dissolved solids are ejected continuously at the surface
of the boiler near the normal level so that the process of is called surface or continuous blow down

The bottom blow down is usually done manually operated valve once per shift or day that is why it is
sometimes called manual blow down but the surface blow down is performed automatically using an
electronic control unit(ECU) which senses the thermal conductivity of the steam. Due to this bottom blow
down is called automatic blow down. So for the boiler to stay healthy, a substantial amount of hot water is
ejected through both sources of blow down. Obviously it is heat loss which reduces boiler efficiency because
we loss the heat we input to bring the water to this degree of hotness. Since blow down is inevitable, it is
better to have a way to recover the heat the hot water contains before it is discharged to the sewer system.

The blow down water before it goes to the discharge is allowed to pass through the blow down tank almost at
atmospheric pressure so that some percentage of the water flashes off due to the pressure decrease at constant
temperature. The flash steam contains almost half the energy of the blow down water. Among the many
choices of recovering the heat of blow down allowing the flash steam to the de-aerator and the remaining hot
water to the heat exchanger to heat the makeup water suits our boiler system.

But the bottom blow down is intermittent that means large amount of water is blown down once in eight hours
for about a minute. In addition, once in a week the manual blow down valve is left opened till the water level
drops to the lower water level to check the status of the level sensor and level switch. So to supply a constant
amount of steam to the de-aerator and constant flow of water to the heat exchanger, steam and hot water
reservoir is required.

Installing the heat recovery system benefits the company because it has the following advantages
34
  It recovers the heat lost with both the residual blow down and the vent steam
 It saves the water used to cool the residual blow down
 It saves the steam required to heat the makeup water in the feed water heater and to expel oxygen and
other dissolved gasses in the de-aerator
 It saves the fuel cost to bring the blow down water to the blow down temperature and electricity to
bring it to the boiler pressure

1.1. project summery

Blow down is a simple fact of boiler operation which occurs when water is removed from the steam boiler while it is
operating. Since there are two groups of impurities the process of blowing down happens in two ways at two boiler
positions. The suspended particles are ejected periodically at the bottom of the boiler thus process is called bottom or
periodic blow down and the dissolved solids are ejected continuously at the surface of the boiler near the normal level
so that the process of is called surface or continuous blow down

The bottom blow down is usually done manually operated valve once per shift or day that is why it is
sometimes called manual blow down but the surface blow down is performed automatically using an
electronic control unit(ECU) which senses the thermal conductivity of the steam. Due to this surface blow
down is called automatic blow down. When TDS level increases the thermal conductivity of steam lowers
beyond the set value in the ECU. Then the ECU opens the valve allowing some amount of TDS with hot water
to leave the boiler. So for the boiler to stay healthy, a substantial amount of hot water is ejected through both
sources of blow down. Obviously it is heat loss which reduces boiler efficiency because we loss the heat we
input to bring the water to this degree of hotness. Since blow down is inevitable it is better to have a way to
recover the heat the hot water contains before it is discharged to the sewer system.
Installing the heat recovery system benefits the company because it has the following advantages
 It recovers the heat lost with both the bottom blow down and the surface blow down.
 It saves the steam required to heat the makeup water in the feed water heater and to expel oxygen and
other dissolved gasses in the de-aerator

 It saves the fuel cost to bring the blow down water to the blow down temperature and electricity to
bring it to the boiler pressure.
1.2. Problem Statement
There is continues blow down ejecting the hot water from the boiler losing the heat (there by an efficiency
drop) the emission of co2 and losing of steam water are concern of the environment. To make the matters
worth the blow down rate drastically increases as the water treatment plant efficiency drops. So the economic
feasibility of the company is coming to down. For this mater we try to solve this by designing hot storage tank
and heat exchanger.

35
1.3. Objective
1.3.1. Main objective
The main objective of this project is to design boiler blow down heat recovery system which will recover the
heat lost due to boiler blow down
1.3.2. Specific objectives
 Collect the required data

 Analyze the economic feasibility of heat recovery system

 Decide on how the heat recovery system looks

 Design hot water storage tank

 Design heat exchanger

 Select servo meters

 Design piping

 Design insulation

 Analyze the cost

1.4. Limitation of the project

Due to the following limitations, we have been able to design some parts of boiler blow down heat recovery
system. Limitations include -

 limitation of time given(due to COVID-19)

 Limitation of internet access
 Limitation of available information on a certain period etc.
 Limitation of computer access
 Limitation of consistency due to war

36
 CHAPTER TWO
2. Literature Review
Krum semkoy [1] carried out study for the evaluation of the potential heat energy saving through technology
optimization and improved heat recovery. Heat network analysis is carried out using redesign of the
technology based on process integration. The heat network analysis have characteristics of; quick estimation
of the potential saving ,limited system analysis requirements, process integration , local and output energy
reduction, low grade heat recovery. A case study shown that overall impact of the improved technology results
in 30% heat saving and about 2.7 times reduction of NOx emission and 70˚c hot water can be generated from
recovered heat.
Subodh Panda [2] analyzed that neural network proves to be an efficient modeling system for calculation and
optimization of the Blow down. It significantly reduces the frequency of deviations and the degree of
deviation of the TDS that can reduce indirect losses. A case study shown that if we use the normal controller
then the tripping of boiler during the load fluctuation which is undesirable. The result has shown the
operational difference between various controllers. It is shown that for the optimization of the blow down
system and reduces the tripping problem during the loads; ANN (artificial neural network) controller is more
suitable rather than conventional PI (proportional integral) controller. The ANN model is more accurate and
efficient making the system robust and reliable as compared to the former
Mousas.mohsen [3] studied on the potential of industrial waste water reuse in thermal power plant. Carried out
the review on process involved industrial waste generation and water requirement. A case study shown that
amount of waste water is reduced by the water treatment system, blow down heat recovery system and using
sewage treatment plant effluent as water. It can show that water and energy can very likely conserved by good
operating conditions, cleaning techniques using minimum water
Petre stehilk [4] described and discussed about the characteristics and specific features of heat transfer is
important process in waste-to-energy system. Example evolved of heat exchanger for heat recovery system,
their design, arrangement and optimization CFD (computational fluid dynamics) is used for improved design
and troubleshooting in Heat transfer equipment and the heat exchangers experiment. A shopestigated support
based on a computational and modeling for improved or optimize the design of heat exchangers method was
as below;
1) Simulation based on energy and mass balance
2) Thermal and hydraulic calculation of heat exchangers
3) CFD (Computational fluid dynamics) approach
4) Optimization
5) Heat integration

37
From the case study it was observed that a computational support which unambiguously belongs to efficient
tool of up to date heat design , Through the example result it is shown that benefits of using CFD is both for
improved design or optimize design and troubleshooting of the problems.
D.Madhav, L.Ramesh “Heat Recovery through Boiler Blow down Tank” May 2013. Has presented a paper
Steam generators are widely used in industries forseveral purposes like power production, processing, heating
etc.In industry steam generators are the major fuel consumers. In anormal steam generator about 4% of hot
water is wasted asblow down. Due to this, a large amount of heat energy is wasted.This project aims to bring a
heat recovery system to preventheat losses; so that a large savings can be madeBlow down water carries
thermal energy in the form ofsteam that can be reused may result in improve the boiler efficiency.

Keerthi R Lekshmi, Vandana S Pillai “Boiler Blow down Analysis In An Industrial Boiler”07 (July. 2015),
has presented a paper boiler blow down analysis and energy savings study has been carried out in an industrial
establishment. Steam boilers need to be blow down to control the level of TDS in the boiler wate

2.1. Methodology For Design Of Boiler Heat Recovery System

Firstly, in our project, we used drawing materials; computers and we have gotten data from different resource
like written books, internet, asking peoples and literature reviews. In the process of idea generation and make,
a planning of the overall progress to make sure the project can be finished on schedule. In this project, we are
going to solve the problem by the following steps:

1. Identifying the problem by carefully understanding the working of the total boiler system

2. Collecting data, primarily by interviewing the boiler plant operators, recording or measuring using available
equipment’s and observing directly from the gauges and different meters and secondarily by surveying the
company documents and records and by searching on the web.

3. Do further research and survey literatures on the subject by looking on the boiler plant history and reading
other boiler plants literature.

4. Check the economic feasibility by calculating the energy and cost saving using both bottom and continuous
blow down rate.

5. Decide on the heat recovery system after analyzing many ways of recovering heat the most ideal system is
selected as per the flow, temperature and physical requirement.

6. Design hot water storage tank by using the pressure vessel design principle and checking the thickness back
against hydrostatic pressure.

38
7. Deign the heat exchanger using the temperature range, allowable pressure drop, available floor area and the
going through long iterative calculation to get the final and nearly ideal heat transfer capability.

8. Select the servo meters by using the temperature and flow rate range of the heat recovery system.

9. Design piping by calculating the overall pressure drop across the pipe

10. Design insulation by calculating the critical thickness of insulation

2.2. Selection of material

Stainless steel is a class of iron-based alloys with a minimum chromium content of. It is characterized by its
superior resistance to corrosion in comparison to other steels.[19]

2.2.1. Corrosion resistance

The corrosion resistance of stainless steel is mostly a result of the chromium content. A stable layer of
chromium oxide is formed on the surface of the steel, which prevents chemical reactions with the bulk of the
material. This oxide layer is extremely thin, 2 nm – 3 nm in thickness, is passive (highly resistant to
corrosion), tenacious (adheres well to the bulk) and self-healing (reforms when cracked or damaged).[19]

2.2.2. Mechanical properties

As the term stainless steel encompasses a wide range of materials, the mechanical properties, of course, are
quite diverse. In general, the values tested for include yield strength, tensile strength, ductility, hardness,
toughness, creep resistance and fatigue resistance. [19]

2.2.3. Electric & Magnetic properties

Stainless steel is a relatively poor conductor of electricity

2.2.4. Recycling

All stainless steels are completely recyclable. As they contain significant amounts of valuable elements such
as chromium and nickel, recycling of scrap stainless steel is in fact extremely cost-effective. Modern stainless
steels are usually manufactured with 60% scrap, including reclaimed scrap, such as from consumer products
and industrial equipment, and industrial scrap, such as off cuts from the manufacturing process.[19]

Generally, due to this property we select stainless steel for our design.

2.3. Selection of Types of joint

39
The advent of welded tanks provided opportunities for new tank configurations, but the greatest
advantage of welded over riveted tanks was the development of smooth structures with much lower
maintenance costs than was possible with lapped, riveted seams. Manual, semiautomatic, and automatic
welding processes have improved continually over the years, offering increased economy and strength. So
we select welded types of joints.[19]

40
 CHAPTER THREE
3. Detail Design And Analysis
3.1. Collected data or specifications
 Number of boilers ……………………………………2
 Boiler capacity ……………………………………….10000kg/hr
 Average boiler pressure for boiler 1 ………………….8 bar
 Average boiler pressure for boiler 2…………………..7.3 bar
 Estimated boiler efficiency……………………………70%
 Flash pressure……………………………………….…2 bar
 Boiler 1 TDS (average of 29 days) ……………………3137.345ppm
 Boiler 2 TDS(average of29 days)…………………...…892.26 ppm
 Feed TDS (average of 29 days)………………………..76.96 ppm
 Make up water temperature(average)……………….…25 °c
 Mass flow rate of makeup water(average)……………. 0.399 kg/s
 Furnace oil calorific value……………………………..10000 kcal/kg
 Furnace oil cost ………………………………………. 13.82 ETB/kg=348.3ETB/million BTU
 Overall operating hours (for boiler 1)………………..... 94076 hours
 Overall operating hours (for boiler 2)…………………. 91106 hours
 Age of boiler (both)……………………………….……15 years
 Average duration of bottom blow down (for boiler 1) ….40 seconds
 Average duration of bottom blow down (for boiler 2)…. 36 seconds
 Diameter of bottom blow down pipe……………………50 mm
 Daily usage of furnace oil (average)…………………… 8000 litters
 Co2 emission of furnace oil ……………………...……0.22 kg/litter of oil

3.2. Economic Feasibility

3.2.1. Continuous Blow Down Rate
The continuous blow down helps in keeping the TDS level of the boiler lower. The amount of water blown
down by a continuous blow down system depends on the boiler and feed TDS.
The percentage of feed water blown down by this system is calculated as
feed tds
% blown down = ×100
boiler tds−feed tds

For boiler 1

41
 76.96
 %blow down = × 100
3137.345−76.96
=2.52%
I.e. 2.52%of feed water is blown down through continuous blow down vale

Multiplying the percentage blow down with the rated boiler capacity we can get the blow down rate

feed tds
 Blow down rate = × boiler capacity
boiler tds−feedd tds
76.96
= ×10000 kg/hr
3137.345−76.96

= 252 kg/hr

For boiler 2

76.96
 %blow down = × 100
892.26−76.96
= 9.44 %
76.96
 Blow down rate = ×10000 kg/hr
892.26−76.96
= 944 kg/hr

Totally 1196 kg/hr hot water is ejected from both boilers only due to continuous blow down rate

3.2.2. Bottom blow down rate

The blow down tank and piping are designed based on the efficiency of water treatment plant and the boiler
working condition. The bottom blow down duration is guided by both the feed and boiler water chemistry.
Having the boiler pressure and the blow down pipe size it is possible to
estimate the bottom blow down rate from the graph Using pipe size of 50 mm diameter for both boilers with
respective pressure the bottom blow, based on 8m total equivalent length:

42
 Figure 17 Approximate bottom blow down rate [11]

For boiler 1 at 8 bar the rate is 10 kg/s

For boiler 2 at 7.3 bar the rate is 9 kg/s
Multiplying it with the average blow down duration gives the amount of water rejected which is necessary to
design the hot water and steam reservoir.

For boiler 1, mass of water=10kg/s×40s=400kg

For boiler 2,mass of water=9kg/s×36s=324kg

So the total amount of water rejected during bottom blow down per shift is

400kg+324kg=724kg

Since there are three shift in a day which lasts 8 hours each the average rate of hot water flowing to the flash
tank if we take the intermittent blow down as continuous is

724kg/8hrs=90.5kg/hr

3.2.3. Cost saving

The amount of heat recovered from the blow down water depends on the

 Blow down rate

 The boiler operating pressure and temperature
 The temperature of makeup water

Using the blow down rate, the amount of heat that can be recovered from this amount of water at boiler
pressure and temperature is estimated from the standard table of boiler of 100000 lb/hr capacity.
43
Table 1 Recoverable heats from boiler blow down[10]

Heat Recovered, Million Btu per hour, (MM Btu/hr)

%blow down Steam Pressure, psig

50 100 150 250 300

2 0.45 0.5 0.55 0.65 0.65

4 0.9 1.0 1.1 1.3 1.3

6 1.3 1.5 1.7 1.9 2.0

8 1.7 2.0 2.2 2.6 2.7

10 2.2 2.5 2.8 3.2 3.3

20 4.4 5.0 5.6 6.4 6.6

So from the table at the respective boiler pressure and %blow down and interpolating gives
For boiler 1, at 8 bar (116 psi) and 2.52% the heat recovered is 0.6502 MM BTU/hr
For boiler2, at 7.3 bar (105.8 psi) and 9.44% the heat recovered is 2.392MMBTU/hr
So this much amount of heat will be recovered if 100000 lb/hr boiler operating at 8 and 7.3 bars is used.

To account to our case we have to calculate the annual energy saving

boiler capacity operating hours ∈ayear

 Annual energy saving= heat recovered × ( )×( )
100000 boiler efficiency

total operation hour of boiler

Operating hours in a year=
age of boiler

44
 94076 hrs
So for boiler 1 operation hour = = 6271.73 hrs/year
15 years

6271.73
Annual energy saving = 0.6502׿ ) × ( ¿= 1284.3 MM BTU/year
0.7

91106 hrs
For boiler 2 operation hour = =6073.73hrs/year
15 years

6073.73
Annual energy saving = 2.392 ׿ ) × ( ¿= 4585.65MM BTU/year
0.7

For both boilers the total energy saving is =4585.65 + 1284.3 =5869.95 MM BTU/year

Then the total cost saving = annual cost saving ×cost of fuel

=5869.95MM BTU/ year ×348.3 ETB/MM BTU

= 2044503.585 ETB/year

The bottom blow down rate increases the annual cost saving by more than 154705 ETB which results in total
cost saving of 2,199,208.3 ETB which is equivalent to 302.6 litters/day. So the heat recovery system could
save more than 3.7 % of furnace oil used. Again on average it will reduce 65.24 kg of co2 per day. The
installation of heat recovery system looks feasible and recommendable as it can be deduced from the
calculation. It seems a large amount of money exceptionally when seen from the poverty we are with.

3.3. Heat Recovery System

Installing a heat recovery system for a boiler system can save a considerable amount of money and help in
achieving healthy steam generation.
Due to the instant pressure decrease when the blow down water flows to flash tank some of the water flashes
off, thus the heat is wasted in two forms. This obliges to have two ways of recovering heat
 Flash steam recovery to the de-aerator
 Heat recovery using the heat exchanger
The De-aerator tank in boiler acts as a Feed Water Tank to store cold and hot fluid in order to remove
dissolved air or non-condensable gases from the fluid. De-aerating feed tank helps in removing non-
condensable gases from a feed.

De-aerator Tanks Uses:-Water or any fluid which is used as a medium for heat transfer generally contains
Oxygen and other non-condensable gases in it. These gases dissolved in a fluid acts as an insulation to heat
transfer. Due to the presence of these gases in a fluid, heat transfer rates from fuel to fluid is generally reduced
which in turn will increase the fuel required for heating, thereby decreasing the efficiency.

45
In de-aerator tank ( aka Feed Water Tank), carbon dioxide (CO2), Non-dissolved Gas,  and oxygen (O2) are
released as gases and combine with water (H2O) to form carbonic acid, (H2CO3).Since steam is distilled
water, the flash steam is pure to use it back to the de-aerator to expel oxygen and other dissolved gasses.

Since steam is distilled water, the flash steam is pure to use it back to the de-aerator to expel oxygen and other
dissolved gasses. To accommodate the intermittent blow down with flow rate requirement of de-aerator and
heat exchanger, servo meter and hot water storage tank is used respectively. The percentage of water which
flashes into steam depends on
 the pressure difference between the boiler and the flash tank

 the design of flash tank

H b−H f
% flash = ×100 where H b = heat at boiler pressure
H fg

720.9−504.7
= ×100 = 9.82% for boiler 1 H f = heat at flash pressure
2201.6

704.5−504.7
= ×100 = 9.075% for boiler 2 H fg = latent heat at flash pressure
2201.6

The percentage is higher than these if we consider the weight of boiler water in case of bottom blow down but
it is not that much considerable for small size boilers. The remaining water is allowed to pass through heat
exchanger to heat the makeup water and thereby to be cooled avoiding the use of cooling water
The mass flow of water which will goes to heat exchanger is

400 kg
For boiler 1 = ( +252 kg/hr) – 0.0982¿ +252 kg/hr)
8 hr

= 272.344 kg/hr

324 kg 324 kg
For boiler 2 = ( + 944 kg/hr) – 0.09075 ( + 944 kg/hr)
8 hr 8 hr

= 895.16 kg/hr

The total mass flow of water = 895.16kg/hr +272.344kg/hr = 1167.5 kg//hr = 0.324 kg/s. so we need a storage
tank to supply a constant supply of hot water to the heat exchanger due to two reasons. These are

 when bottom blowing down if the total hot water is allowed to pass through the heat exchanger, it
causes the makeup water which is at lower pressure (1 bar in the de-aerator) to vaporize before the feed
pump which is risky to the pump

46
  it is better to supply constant flow of fluid to heat exchanger to avoid thermal crack of heat transferring
surfaces
Diagrammatically the heat recovery system is to be combined with the boiler system as follows. Both the
bottom and surface blow down water flows to the flash tank. Part of it flashes to steam and goes to the de-
aerator. The servo meter adjusts the valve of the steam pipe as per the flow rate of the flash steam. The
remaining (residual blow down) flows to the hot water storage tank and the servo meter adjusts the valve to
feed the required hot water to the heat exchanger as per the flow rate or outlet temperature of the makeup
water to heat up the makeup water and then discharged.

G
A E
F

A C

Figure 18 heat recovery system integrated with the boiler system

Where;

A=Boilers, B=Flash tank, C=Hot water tank, D=Heat exchanger, E=De-aerator, F=Boiler feed water tank,
G=Steam storage tank.
47
3.4. Hot Water Storage Tank Design
A vessel must be designed to withstand the maximum pressure to which it is likely to be subjected in
operation. For vessels under internal pressure, the design pressure is normally taken as the pressure at which
the relief device is set. This will normally be 5 to 10 per cent above the normal Working pressure, to avoid
spurious operation during minor process upsets [9].

Due to the bottom blow down the flow rate of water to the heat recovery system varies. So the amount of heat
to be recovered fluctuates. So we need to have some mechanisms which supplies constant flow rates to the
system. The extra hot water and steam is to be stored and used continuously throughout the boiler operation
hour.
The storage tank is subjected to loads from
 Hydrostatic pressure of the fluid
 Internal pressure of the fluid
 Thermal stresses

The tank is designed based on the pressure vessel design principle and then the thickness is checked for the
hydrostatic pressure

3.5. Design of Shell

Step 1 specify the design parameters

The strength of metals decreases with increasing temperature so the maximum allowable design stress will
depend on the material temperature. The design temperature at which the design stress is evaluated should be
taken as the maximum working temperature of the material, with due allowance for any uncertainty involved
in predicting vessel wall temperatures [9]

 Design temperature =150 °c

 Design pressure =2 bar + 10% of 2 bar = 2.2 bar, since PD = P+ P*10%[9]
 Design stress= 130 Mpa at 150 °c
 Design stress factor = 1.5 for minimum yield stress at design temperature
 Type of the vessel is to be cylindrical since it is commonly used for storage of fluids at about
atmospheric pressure.
 The head is to be semi hemispherical since it is strong enough to withstand the hydrostatic
pressure at larger depth.
 The orientation of the vessel is to be vertical since we have less floor area and almost no
wind load (indoor application).
 Take fully radio graphed joint with joint efficiency 100 % (E=1).
48
  The support is to be leg support because there is no that much concerning wind load since it
is used for indoor application
Step 2 calculate the----------------factor

P
F= Where, P=design pressure , Psi = 0.22 MPa=145.034 Psi
CSE

C=corrosion allowance ,∈¿ = 2mm = 0.0787in

S = stress value of material, Psi = 18854.9

145.034 Psi
F= = 0.098 in-1
¿¿
¿

Step 3 Select the diameter from the table

Figure 19 chart for determining the vessel diameter[11]

Based on the given volume=0.724 m3=25.6 ft 3, the vessel diameter =2.2ft =0.671m=671mm.

4V 4 × 0.724
So from here the cylinder height is calculated as h= 2 = = 1.94m
π Di π ¿¿¿

49
Step 4 calculate the cylinder thickness

PR
t= + c = ( 145.034 Psi ) ¿ ¿ =0.102in+2 =2.59mm+2=4.59mm ≈ 5mm
SE−0.6 P

since 1in=25.4mm

Figure 20 cylinder geometry Figure 21 cylinder

3.5.1 Stress Analysis for the shell

First let’s check whether the vessel is thick or thin cylinder, to do so

t 5 mm 1
= =0.015< so it is thin cylinder
r 335.5 mm 10

−P(D 0 ) −( 0.22 MPa ) (345.5 mm)

a) Hoop stress = σ h= = = -7.6 MPa
2t 2(5 mm)
b) Radial stress , σ r= 0 ,by definition
−P (D 0) σh −7.6 MPa
c) Longitudinal stress ,σ l= = = = -3.8 Mpa
4t 2 2
Identify principal stresses in terms of “Average” stresses:
σ 1 = σ r = 0 MPa
σ 2 = σ l= -3.8 MPa
σ 3 = σ h = -7.6MPa
Calculate maximum shear stress
σ 1−σ 2 0−(−7.6)
τ max= = = 3.8 MPa this is by far the lowest of the material strength of the selected material.
2 2

50
Figure 22 stress conditions of the cylindrical vessel[11]

3.6. Design of Head

calculate the cylinder head thickness

PR
t= +c=( 145.034 Psi ) ¿¿ 0.0508in+2= 1.29mm+2=3.29≈ 4 mm
2 SE−0.2 P

Since the two thicknesses should be approximately equal for efficient welding, we approximate thickness of
head to an equal thickness with the shell.

51
Figure 23 semi-spherical head geometry Figure 24 Head

3.6.1. Stress analysis of head

Hoop stress (σh )
PdDi
σh=
2t
671
σh=2.2×
2 ×5
σh =147.62Mpa
147.62Mpa<165Mpa,So our design is safe.
Longitudinal stress(σl )
PdDi
σl=
4t
671
σl=2.2×
4 ×5
σl=73.81 Mpa<165 MPa So our design is safe.

3.7. Design of support

Almost no wind load (indoor application),so neglecting the wind weight.
Calculating the total weight, hot tank material=AISI3D4 Stainless steel

W t =W s h ell+W h ead

W s h ell=π D mtl ρ sg where D m= mean diameter of shell

t=thickness of the shell

l=length of the shell
ρ s=¿Density of shell material

G=Gravity Of The Earth (9.81m/S2)

52
Figure 25 Leg Support

Hence, Dm= D i+2t=671mm+2*5mm=681mm;t=5mm

L=1940mm

ρ s=8000kg/m3

W s h ell= π × 681×1940×8000×5×9.81=1627.82 N
Weight of the medium(water)=mass×gravity, mass=volume×density
M=0.724×1000=724kg;then weight of water=724×9.81=7102.44N
ρs (0.681 m)3
Weight of head=π×d ×g=π×
3×
×9.81m/s2×8000kg/m3=4864.18N
16 16

For two head=4864.12×2=9728.37N

W total =1627.82+7102.44+9728.37=18458.63N

3.7.1. Stress Analysis for Leg Support

We Need three Number Of Legs; Stress Of Tank Material(Stainless Steel)=165N/mm2

Q=w 0/4=18458.63N/3=6152.88N

Area of leg(A)=Q/stress allowable=6152.88N/165N/mm2=37.3mm2

The leg is square cross section; then width and breadth of the leg is equal

A=W×B=W2; W=√ A =√ 37.3 mm 2=6.1mm

Length of the leg is from optimum pressure vessel proportional L=2d=2×681mm=mm=1.1362m

53
 Figure 26 assemblies drawing of hot storage tank

3.8. Heat Exchanger Design

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.
A heat exchanger is a system used to transfer heat between two or more fluids. Heat exchangers are used in
both cooling and heating processes.[14] The fluids may be separated by a solid wall to prevent mixing or they
may be in direct contact.[15]To transfer the heat from the blow down water to the makeup water a heat
exchanger is designed as per the

 Duty

 Flow rate and

 Physical requirement
Plate heat exchanger is selected for this heat recovery system because
 The boiler room is congested so we have less floor area

 The residual blow down is fouling so we need high turbulence flow

 The effluent has to be lower temperature and recovering available heat is required so we need a closer
temperature approach

54
  The company plans to increase its production rate in the coming 2 to 3 years so additional boiler is to
be installed to satisfy the steam requirement of the expansion. The blow down rate will increase and so
will the makeup water requirement. Obviously a higher capacity heat recovery system will be required
so the heat exchanger must be expandable
 The water is somewhat corrosive so the material selected is stainless steel (316)
 Since the residual blow down is muddy, the heat exchanger needs frequent cleaning. The heat
exchanger to be selected must be easy to dismantle. That is why gasket type plate heat exchanger is
selected
 The gasket is to be ethylene propylene rubber

Step 1 Define the duty (heat transfer rate), flow rates, outlet and inlet temperatures of both Streams

The residual blow down rate=mh = 0.318 kg/s

Make up water flow rate =mc = 0.376 kg/s

T h∈¿ ¿ =120.2 ℃ T cin = 70℃

T hout = T cin+ 15 °c =70℃ +15℃ =85℃

T cout =?

The closer temp approach used the larger will be the heat transfer area required for a given duty. When the het
exchange is between the process fluids for heat recovery the optimum approach temperature will normally not
be lower than 10 °c, but plate heat exchanger is good in temp approach so take 15 °c itself.

The heat transfer rate is calculated using the hot stream

σ h= mh×cph (T hin- T hout )

= 0.324 ×4.19 (120.2-85)

= 47.78 kj/s

To find the out let temperature of the makeup water

σ h=Qc = mc (Tcout- Tcin)

=0.399 ×4.19(Tcout-70)

Tcout=98.58℃ . This is still lower than the saturation temperature of makeup water at a pressure before the
de-aerator (> 1 bar). So no threat of flashing and the assumed approach temperature is acceptable. On average
this temperature rise would result in more than 1.95% boiler efficiency increase

55
Step 2 calculate the logarithmic mean temperature difference (LMTD)

Δ T 1−∆ T 2
where , Δ T 1
LMTD = ΔT1 = T hin- Tcout = 120.2 – 98.58 = 21.6℃
ln
ΔT2

21.6−15
∆T 2
= 21.6 =T hout - Tcin = 85-70 =15℃
ln
15

= 18.44 ℃

Step 3 determine the logarithmic mean temperature difference correction factor (f) from the graph using
NTU and taking single pass 1:1 arrangement

Figure 27 LMTD correction factor for plate heat exchanger [11]

∆T
For this purpose NTU = where, ∆T = T 2-T 1 taking the largest of the two streams
LMTD

120.2−85
= 18.44

=1.91

Then from the graph f = 0.97

T lm= f × LMTD = 0.97 ×18.44 = 7.88 °C

Step 4 estimates the overall heat transfer coefficient from table

For soft treated water take 3500 W/m.℃

56
Step 5 calculate the total surface area required to transfer the heat load

Qh= UAT lm

Qh 3
Then rearranging A= = 108.88 ×10 = 1.5 m2
U T lm 3500× 17.88

Step 6 calculate the number of plates

To select the plate surface area

 Plate thickness-………….……0.5 to 3 mm
 Gap between plates………… ..1.5 to 5 mm
 Plate surface area ……………..0.003 to 1.5 m2
 Plate length to width ratio ……2 to 3
 Size of heat exchanger ………..0.03 to 1500 m2
 Stainless steel 316 thermal conductivity kw= 16.5 W/m.k
 Prandtl number of water
 Gasket is to be ethylene propylene rubber with approximate temperature limit 150 °c and
fluid to be wide range of chemicals

Take the plate length = 0.5 m and plate length to width ratio =2.5

Then plate width =0.2 m and plate area = 0.5 ×0.2 = 0.1m2

total surface area 1.5

Finally the number of plates = = = 15 say 17 plates to make an even number of channels.
plate area 0.1
17−1
Number of channels per pass= =8
2

Step 7 decide on the flow arrangement and number of passes.

Figure 28 single pass counter flow arrangement [12]

57
Step 8 calculate the film heat transfer coefficient
Take the plate spacing be 2 mm

Then the film or channel cross sectional area = Plate spacing × plate width

= 2×10−3 × 0.2 = 4 ×10−4 m2

The hydraulic mean diameter De= 2 ×plate spacing = 2 ×2×10−3= 4×10−3m

For blow down water

mh 1 1
Channel velocity =up= × ×
ρ Area of channel number of channel

0.324 1 1
= × ×
1000 4 ×10−4 8

= 0.10125m/s

ρup De 1000× 0.10125 ×4 ×10−3

Reynolds number Re =
μ
= =1447
0.00028

Nusselt number Nu = 0.26 ℜ0.65 pr 0.4

= 0.26×1447 0.65 5.7 0.4 = 59.1

Nu kw 59.1× 0.59
Film heat transfer coefficient = hp = = −3 = 8716 W/m.℃
De 4 ×10

For makeup water

Channel velocity = 0.125m/s

Re = 1782

Nu = 67.65

hp = 9979 W/m.℃

Step 9 overall heat transfer coefficient

1
U = 1 + 1 + tp + 1 + 1
h p fh kp h p fc

58
 1
−3
= 1 1 0.75 ×10 1 1 = 2540 W/m.℃ . It is too low than required for 8 channels per
+ + + +
8716 15000 16.5 9979 15000
pass to transfer the given heat duty. So we have to increase the number of channels. Let it be 16 channels per
pass and going back to step 8.

For blow down water For makeup water

Up = 0.0506 m/s Up = 0.0624m/s

Re = 723 Re = 891

Nu = 37.66 Nu = 43.11

hp = 5554 W/m.℃ hp = 6359 W/m.℃

Then the refined overall heat transfer coefficient is

1
−3
U= 1 1 0.75 ×10 1 1 = 1934 W/m.℃ .
+ + + +
5554 15000 16.5 6359 15000

8
The required U for the 16 channels = 3500× =1750 so 16 channels per pass are satisfactory for the given
16
heat duty. So the required numbers of plates are 2×16+ 1=33

3.9. Pressure drop

 In a plate heat exchanger the corrugations of the plate and the port causes pressure drop. The
pressure drop must not be larger than the allowable pressure drop for the fluid based on the
viscosity Allowable pressure drop for fluid with viscosity
< 1 mN.S/m2 , ∆p = 35 KN/m2
1 to 10 mN.S/m2, ∆p = 50 -70 KN/m 2

So for water at mean temperature the viscosity is 0.28 mN.S/ m2 and then the allowable pressure drop is 35KN/
m2

The total pressure drop, ∆pt, comprises of

 pressure drop across the plate

 pressure drop across the port

∆pt =∆pp+∆ppt

For blow down water

59
 ( )
2
Lp ρ Up
Pressure drop across the plate, ∆pp= 8Jf ,
De 2

where, Jf = 0.6 ℜ−0.3 = 0.6×723−0.3 = 0.0833

0.5 1000 ×0.0506 2

=8× 0.0833( ) = 106.6 Pa
4 ×10−3 2

ρUpt 2
Pressure drop across the port, ∆ppt = 1.3( )× Np where , Np = number of passes = 1
2

2
mp
And Upt = Ap = area of port = π De = π ¿ ¿ = 1.256×10−5
ρAp 4

0.324
= −5 = 25.8 m/s
1000× 1.256 ×10

1000× 25.82
Then, ∆ppt = 1.3( )×1 =33.272 kpa
2

∆pt =∆pp+∆ppt = 0.1066+33.272 = 33.38 kpa

For makeup water

∆pp = 304.5 Pa

∆ppt = 32.8 kPa

∆ppt=∆pp+∆ppt =0.3045+32.8 = 33.103 kPa

The pressure drop is below the allowable pressure drop for both streams. So the plate heat exchanger is
satisfactory for this heat recovery purpose

3.10. Servo Meter Selection

Flow Meter: - is just to sense the amount of flash steam and then increase and decrease the opening of the
steam pipe which brings the steam for feed tank from steam distributer. As the flow rate of flash steam
increases the steam pipe valve opening is minimized and vice versa.

3.11. Piping design

The pipe may have elbows, valves, gates etc, so the equivalent length and pressure drop is calculated

60
Optimum pipe diameter
The capital cost of a pipe run increases with diameter, whereas the pumping costs decrease with increasing
diameter. The most economic pipe diameter will be the one which gives the lowest annual operating cost. The
optimum diameter for turbulent flow is
0.52 −0.37
d opt =260 mh ρ =260 ×0.324 0.52 1000−0.37= 11.3 mm take 20 mm

Pressure drop through the pipeline

The pressure drop in a pipe, due to friction, is a function of the fluid flow-rate, fluid density and viscosity,
pipe diameter, pipe surface roughness and the length of the pipe. It can be calculated using the following
equation:
l 2
∆ Pf =8 f ρu , where ∆ Pf = pressure drop, N/m2,
di
f = friction factor,
L = pipe length, m, ≈ 8m
di= pipe inside diameter, m,
ρ=¿fluid density, kg/m3,
u = fluid velocity, m/s = 12.9 m/s

The friction factor is a dependent on the Reynolds number and pipe roughness. It can be found from the chart
below Values for the absolute surface roughness of commonly used pipes are given in Table below

Table 2 absolute roughness of common pipes[13]

Material Absolute roughness, mm

Drawn tubing 0.0015

Commercial steel pipe 0.046

Cast iron pipe 0.26

Concrete pipe 0.3 to 3

61
Figure 29 pipe friction vs. Reynolds number and relative roughness[12]

So for commercial steel pipe and Reynolds number = 18071, f = 0.0090 then

8
∆ Pf =8 × 0.0090× 1000 × 12.92= 1.83 k pa
0.02

Miscellaneous pressure losses

Any obstruction to flow will generate turbulence and cause a pressure drop. So, pipe fittings, such as: bends,
elbows, reducing or enlargement sections, and tee junctions, will increase the pressure drop in a pipeline.
There will also be a pressure drop due to the valves used to isolate equipment and control the fluid flow. The
pressure drop due to these miscellaneous losses can be estimated using either of two methods:
u2
1. As the number of velocity heads, K, lost at each fitting or valve. A velocity head is , meters of
2g
2
u
the fluid, equivalent to ρ N/m2. The total number of velocity heads lost due to all the fittings and valves
2
is added to the pressure drop due to pipe friction.
2. As a length of pipe that would cause the same pressure loss as the fitting or valve as this will be a function
of the pipe diameter, it is expressed as the number of equivalent pipe diameters. The length of pipe to add
to the actual pipe length is found by multiplying the total number of equivalent pipe diameters by the
diameter of the pipe being used. The number of velocity heads lost, or equivalent pipe diameter, is a
characteristic of the particular fitting or type of valve used. Values can be found in handbooks and
manufacturers’ literature. The values for a selected number of fittings and valves are given in Table below
Take five 90mm standard radius elbows, two sudden expansions (tank inlet), two Sharp reductions (tank
outlet) and two Gate valves (1/2 open), the overall miscellaneous pressure losses is the overall
miscellaneous pressure losses is

62
(5× 0.8+2× 0.5+2 ×1.0+2 × 4 ¿ = 15
u2 12.92
The head loss = 15× = 15× = 127.3 pa
2g 2 ×9.81
The total pressure loss is 0.1273+1.83 = 1.96 k pa
So the total pressure drop =33.38+1.96=35.34kpa which is very smaller no need to pump the blow down
water since it is above still above atmospheric pressure. So no difficulty to drain
Table 3 pressure loss in pipe fittings and valves for turbulent flow[11].

Fitting or valve K, number of number of equivalent

velocity heads pipe diameters

45mm standard elbow 0.35 10

45mm long radius elbow 0.2 15

90mm standard radius 0.7 - 0.8 30 – 40

elbow

90mm standard long elbow 0.45 23

90mm square elbow 1.5 75

Tee-entry from leg 1.2 60

Tee-entry into leg 1.8 90

Union and coupling 0.04 2

Sharp reduction (tank 0.5 25

outlet)

3.11.1. Stresses in Pipes

The stresses in pipes due to the internal fluid pressure are determined by Lame's equation.
According to Lame's equation, tangential stress at any radius x,
The tangential stress is maximum at the inner surface (when x = ri) of the pipe and minimum at
The outer surface (when x = ro) of the pipe.
(a) the variation of stress across the thickness of the pipe is taken into account,
63
(b) the internal diameter of the pipe (D) is less than twenty times its wall thickness ( t ) , i.e.
D/t < 20, and
(c) the allowable stress (σt) is less than six times the pressure inside the pipe ( p ) i.e.
σt / p < 6.

tangential stress

p ( ri )2 +(r o)2
σ t= [1 ¿ but r o =¿ ri+ ¿¿ ¿2t
r o 2−r 2i xo

PD
t= +c = 0.22 Mpa × 50 mm +3=3.033 since 1 ¯¿ 100 kpa=0.1 Mpa
2σA 2 ×165 Mpa

t=3.033mm

r o =¿ ¿25mm+3.033=28.033

2
27.5 ( 25 ) 2 (28.033)
σ t= [1+ ]=141.2Mpa
¿¿ (25)2

141.2Mpa<165Mpa,σ t<allowable stress so our design is safe

Radial stress

σ −(r o)2
r=¿
p (r i ) 2
r o 2−r 2i
¿ [1 x ¿
o

σ r=¿0.22 ¿¿ ¿] =-27.5Mpa

27.5Mpa<165Mpa.σ r<¿ ¿Allowable stress so our design is safe

3.12. Insulation design

The storage tanks and the pipe that takes the residual blow down to the heat exchanger and that takes the
heated make up water to the feed water has to be insulated to avoid heat loss to make the boiler room healthier
to work in.

For the tank the insulation material is to be fiber glass with k i 0.04 W/m.℃ from the table below

The critical thickness of insulation for the storage tank will be

64
 k i 0.04
rc= = = 4 mm
h 10

Table 4 thermal conductivities of some insulting material[11]

Material Thermal conductivity W/m C

Air 0.03

Foam, Polyurethane 0.03

Fiber glass 0.04

Corkboard 0.04

Wool Felt 0.05

Cotton 0.06

Sawdust 0.06

Paper 0.18

Wood 0.01-0.02

Sand 0.3

Plaster 0.5

Glass 0.8

Dry Soil 1

Concrete 1.04

For the pipe the insulation material is to be foam polyurethane withk i = 0.03 W/m.℃ so the critical thickness
k i 0.03
of insulation is r c = = 10 = 3 mm
h

65
 CHAPTER FOUR

4. Result And Discussion

4.1 Result
Table 5 Result

Number Components Quantity Dimension material

1 Shell 1 1940mmx671mm Stainless steel

2 Head 2 Dia 671mm Stainless steel

3 Leg 3 1360mmx30mm Stainless steel

4 Pipe 4 8000mmx25mm Stainless steel

4.2. Discussion
In this heat recovery system, we have designed Hot water and steam storage tank parts such as shell, head, and
vessel support. Most of the components are designed by using appropriate formulas, and some of this are
reading from tables and charts. From heat exchanger also designed each component using appropriate
formulas and charts and their safety also checked for strength to avoid failures. Using storage tank remove
dissolved air or non-condensable gases from the fluid and by heat exchanger recover loss of heat.

As we try to discuss in the theoretical part we can match it with the design analysis above by calculating the
required parameters and as much as possible we try to solve the problem for the company .the solution has its
own positive impact for company and costumers like by saving economic aspect and hazard of environment.
The calculated parts are really and practically accepted. We have discussed also the overview of the company
with its image on the costumer as it must use mechanical parts instead of manual power for production of
good quality and quantity.

66
 CHAPTER FIVE

5. Conclusion And Recommendation

5.1. Conclusion
The boiler system is an important energy converting system that mostly used in industries. Then it is essential
to pay attention to energy management and other factors of boilers. Boiler water treatment is the most
important one as it reduces the scale formation inside the boiler. Another main point is heat recovery systems .
The heat recovery system looks economical to install saving very considerable amount of money with very
shorter payback period. It will recover more than 233.6 kW of energy, which means saving more than 3.7% of
furnace oil, which is costly, and pollutant. It increases the boiler efficiency by more than 1.95% and will
reduce 65.42 kg of CO2 emissions per day. Again, it saves more than 31.1 liters of service water per day. it can
be concluded that there is still a lack of improvements in boiler systems. Therefore, installing the heat
recovery system is not avoidable, to overcome all challenges dashen brewery company should implement the
systems in this article, and they can consider the ways to make the boiler system to a more advanced one with
at least 90%.

5.2. Recommendation
When we design some part, we have to collect information from different source. This means the design is
performed by using many references and web sites. So the materials needed for design case must be fulfilled
in order to perform applicable design for all users. The company should have establish a project design,

67
development and expansion board that is able to modify activities, create new ideas and strategies supervise
intern projects to improve customer satisfaction based on current needs.

Boiler system needs to be more efficient to improve continuous development in any industry. It is
impossible to convert all of the energy from one form to another. In boiler systems, also several losses can be
accounted when calculating boiler efficiencies.

In addition to recover heat using blow down we have interested to recommend other effective energy
conservation measurements, such as:

 Insulation should be done in distribution system, heat exchangers etc.

 Improve feed water and make-up water treatment.
 Feed water and make-up water should be pre heated by an economizer
 Flash steam must be utilized.
 Shutdown unnecessary boilers.
 Heat transfer surfaces should be cleaned.
 More efficient pumps and motors should be installed etc.

68
Reference

[1] Krun semkow, emma mooney ,Michael Connolly,Catherine aldley ,”efficiency emprovement through waste heat
reduction” ,applied thermal engineering,70,2014,716-722

[2] Subodh Panda,Bikash SwainSandeep,Mishr,”blowdown losses control in thermal power plant using neural networks”, appied
thermal engineering ,2012
[3] Mousa s. mohsen treatment and reuse of industrial effluents: case study of thermal power plant.
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[4] Petr stelhlik,“heat transfer as an important subjects in waste-to-energy system”,appied thermal engineering,27,2007,1658-1670.
[5] D.Madhav, L.Ramesh “Heat Recovery through Boiler Blow down Tank” May 2013
[6] Keerthi R Lekshmi, Vandana S Pillai “Boiler Blow down Analysis In An Industrial Boiler”07 (July. 2015),
[7] S. Panda, P.S. Ratha, Dr. N. K. Barpanda. 2014.Intelligent system for efficiency enhancing program of
thermal power plant: A Case Study. Int. J. of Advanced Research in Electrical, Electronics and
Instrumentation Engineering.

[8] Keerthi R Lekshmi, Vandana S Pillai. 2015. Boilerblow down analysis in an industrial boiler. IOSRJournal
of Engineering (IOSRJEN). 5: 22-28.

[9] Ernst W., Mariëlle Corsten and C. Galitsky. 2015.Energy efficiency improvement and cost saving
opportunities for petroleum refineries. An EnergyStar® Guide for energy and plant managers, U.S.A.

[10]. Dashen brewery boiler plant operating manual

[11] R.S.khurmi and J.K.Gupta ,text book of machine design, edition 2005

[12]. Yunus A. Cengel, “heat transfer text book”, Second edition, 2001.

[13], Coulson & Richardson’s Chemical Engineering, Volume 6, Fourth Edition 2005

[14] Ahmed T. Al-Sammarraie & Kambiz Vafai (2017) Heat transfer augmentation through convergence
angles in a pipe, Numerical Heat Transfer, Part A: Applications, 72:3, 197-214,
https://dx.doi.org/10.1080/10407782.2017.1372670

[15] Sadik Kakaç; Hongtan Liu (2002). Heat Exchangers: Selection, Rating and Thermal Design (2nd ed.).
CRC Press. ISBN 978-0-8493-0902-1

[16].Dashen brewery water chemistry data book

[17]. Dashen brewery boiler plant operating manual
[18]. Technology of brew and Malt Production, Kunze, 1999GC in England

[19]. AWWA MANUAL M42 Revised Edition]American water work association.

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Main plate drawing

Gasket plate drawing

71
Internally attachment drawing

72
Part four back cover drawing

73
Front cover drawing

74
75