Welcome to

our
presentation
JIMMA UNIVERSITY

JIMMA INSTISTUTE OF TECHNOLOGY

SCHOOL OF CHEMICAL ENGINEERING

RESEARCH METHODS AND PROJECT PROPOSAL (ChEg 5251)

DESIGN OF CONDENSER FOR WORT KETTLE

Introduction
 The brew house is the house where beer production starts. A wort
kettle is one of the machines (tank) used for boiling the wort at
85-95 ºC and the steam is discharged to the environment as
waste.
 A condenser is a device that converts vapor to liquid. There are
different types of condensers but we design surface condenser
(shell and tube type of condenser).
 The steam enters the shell side and the cooling water enters the
tube side. The steam temperature decreases from 85 to 55 ºC and
the cooling water temperature increase from 20 to 45 ºC.
 At the end of condensation, the condensed steam and hot water
mixture enter the hot water tank at a temperature of 50 ºC then
the process keeps cycling.
Statement of the problem
 Bedele brewery factory has many production rooms. Brew
house, packaging house, and yeast room get steam from the
utility.
 In utility, the steam produced by boiling water, fuel, butane
gas, and air. The materials that used to get steam has economic
losses for the factory. 
 For this reason, the company needs searching a way of reusing
the steam liberated as a waste from the wort kittle and save
potential losses that comes from improper energy utilization.
Objective
General Objective
 The general objective of the project is to design of surface
condenser for wort kettle.
Specific Objective
 To design both mechanical parts and thermal aspects of
the condenser
 To calculate different parameters of shell and tube
condenser
 To calculate the cost of the designed condenser and the
cost-saving due to the presence of the condenser
Scope of the study
 The project’s scope includes the selection of
material up to design and data gathering to recover
the evaporated water and the amount of energy used.
Methodology
METHOD
 We have used different methods for designing this condenser in identifying and
solving the problem.
 Starting from data gathering to detailed mathematical calculations, such as
temperature, pressure, time, volume and flow rate readings from displays of the
plant equipment
 As well as using references and literatures for economic analysis and deep
design calculations.
ELEMENTS OF A CONDENSER PLANT
We use different elements to get condensed steam and hot water.
These are:
 A Condenser         
 Hot water tank                                           
 A Pump supplies cooling water to the condenser        
  Supply of cooling water tank                 
  A Pump to remove the condensed steam from the condenser
PROCESS DESCRIPTION IN EACH
ELEMENT 
 The steam, which has 2.4 bar of pressure and 85 º C of temperature,
enters the condenser at the shell side.
 The cooling water from the cool water tank, which has a temperature of
20 º C, enters the tube side of the condenser by using a pump. Cooling
water circulates in the condenser by extracting the heat from the steam
and the steam will be converted to water.
 The cooling water becomes warm water (45 ºC) by the process of
conduction. The warm water leaves at the top of the condenser and enter
into the hot water tank.
 The steam becomes condensed steam (55 ºC) and at the bottom of the
condenser, we remove condensed steam by using a pump
 Finally, the mixture of warm water (45 ºC) and condensed steam (55 ºC)
both enter the hot water tank and the temperature becomes 50 ºC that is
needed for the process.
wort
kettle

conde
nser

Hot
coolin
water
g
tank
water
tank

Figure 1: Design to get hot water by using the elements

 RESULT AND DISCUSSION
RESULT
CONDENSER DESIGN CALCULATIONS DATA WITH UNITS AND COST OF
DESIGNED CONDENSER
Table 1:Results of the designed shell and tube condenser with cost
 THE ANNUAL COST OF STEAM
 The chart below shows that the annual cost of the steam difference between if the
company used the designed condenser to condense steam from the wort kettle and
 If the company used steam from the boiler. When it used condensed steam the annual
cost of steam is 268155.2902$/year if not the annual cost becomes
402232.976$/year.
600000

500000
Total annual cost of steam$/year

400000

300000
272319.406

200000

268155.29
100000
123485

0 6428.57
Using condensed steam Using steam from boiler

Oil Butane Steam cost

Figure 2: Annual cost of steam

 DISCUSSION
 On the first table based on the data our results show that the
designed Shell and tube condenser is acceptable according to its
standard.
 On this project, measuring materials such as pressure gauge (to
measure steam pressure) and flow meter (to measure flow rate)
cannot easily gain. Because of these facts, we need to use
assumptions from steam distribution data and wort kettle data. So
using a measuring instrument is necessary to design effectively.
 The second chart shows that the annual cost of steam distribution by
comparing both using condensed steam and steam boiler. If the
company uses steam from the boiler, the company will lose more
amount of cost than using condensed steam by the condenser.
 On behalf of the chart, the cost of steam will vary year to year for
that matter the cost of oil and butane gas is not constant. 
 CONCLUSION
 Instead of removing the steam from the wort kettle, it is better to
install a steam condenser since it will recover much amount of
energy and as a result, it will reduce steam cost.
 Design of both mechanical and thermal parts of the condenser is
necessary to know what type of condenser (based on measuring
and calculating data) needed to condense that steam and to get
the designed cost of the condenser.
 The Design cost of the condenser preventing unnecessary cost
out to the condenser and help to get the needed amount of
condensed steam.
RECOMMENDATION
we want to recommend that:-
The company can minimize the electrical energy power by using
steam energy power to minimize the electric energy power the
company should design a turbine by participating engineers or else
can install it by buying.
The generated steam from wort kettle fed to a single turbine, it
generates electricity, and it increases profitability of the company.
The mixture of warm water (45 ºC) and condensed steam (55
ºC) both enter the hot water tank and the temperature becomes 50
ºC that needed for the process (50-60 ºC). However, if the
company think the temperature is not enough the company can
install wort pre-heater by using hot condensate.