Welcome to our presentation

A PROJECT REPORT ON
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 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.
4.3 OBJECTIVES
4.3.1 GENERAL OBJECTIVE 
The general objective of the project is to design of surface
condenser for wort kettle.
4.3.2 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 PROJECT
• 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.
LIMITATION OF THE PROJECT
• - Lack of time
• - Source limitation
• - Luck of measuring instrument (pressure gauge and flow meter)
NAME OF AUTOR / YEAR REVIEW OF LITERATURES

DR. Mohd Paver(2017) • Introduce steam condenser are device

in which used for condense steam by
using cooling water
• Condenser can be use with turbine

Grolsch Brewery (the Netherland) • Installed a heat recovery system in its

continuous wort boiling operations

TW Swagelok company(2011) • Solve problem of steam cost

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.
There 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. This process is called condensation. 
• 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
water
cooling
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

402232.98
300000

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.
THANK
YOU!