BAHIR DAR UNIVERSITY

BAHIR DAR INSTITUTE OF TECHNOLOGY

FACULTY OF MECHANICAL AND INDUSTRIAL ENGINEERING
MECHANICAL ENGIREERING PROGRAM
PROJECT TITILE: DESGIN OF HEAT RECOVERY SYSTEM FOR BOILER
BLOW DOWN
INTERNSHIP HOSTING COMPANY: DASHEN BEREWERY SHARE
COMPANY
PREPARED BY:
NAME ID
1.GedionZelalem………………….……..…0800803
2.Mulu Marie………………………….……0801123
3.MarkosDeres……….…………………….0801000
 
 
  Mentor: Mr Tesmegen Assefa
 Let us come to our presentation
general outlines:
Part One: Report Part.
Brief Description Of The Company.
Main Users & Products.
Organizational Structure.
An Internship Experience
The Section We Were Participate.
Work Task Executed.
Engineering Methods & Tools.
Faced & The Way To Overcome It.
Gains During Internship Period.
Recommendation.
Part two: project part
Introduction
Project Summery
Problem Of Statement
Objective
Methodology
Design Analysis
Result & Discussion
Conclusion
Recommendation
Chapter one:
historical background of the s.c
The name Dashen is taken from the famous
mountain Dashen, which is located 100km from the
home of the brewer; Ethiopian highest mountain
Elevation (elevation 4523 meters) and a home for
rare endemic animals. Dashen brewery share
company (DBS.C) is located in historical town of
Gondar, and annually visited by more than 90,000
tourists. The brewery is situated on the area of
85,000 square meters with
buildingareaof12,000sqm.
Main products and services: beer is the main product.

Main customers: The end users/customers are every person aged above 18 years
old. The products are distributed across the country in four regions and three
ware houses. These are:
Region1: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 as well as in the foreign
country such as Australia ,Israel & South Sudan.
Work flow of the company: Gonder

Dashen
Brewery s.c

Beer processing
Utility section Production section
section
Brew Section:
In brew house malt from raw materials stock entered in to mill star. The
type of mill star is white mill. The entered malt milled by roller with the
help of warm water.

Utility section:
It is the backbone of the company. Because, it is the sources of power
supply, air compressor, steam, process water, glycol and purified
carbon dioxide those have significant impact on production. Utility
section comprises many plants.
production room: It consists of Beer filling and packing process of
bottled beer.

a. Un caser b. bottle washer c. pasteurizer d. caser

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.
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.
Work Task Executed
The major tasks that we were involved are:
 Cleaning of boiler system
 Boiler efficiency test
 Conveyer maintenance
 Labeler disassembly, cleaning , servicing and assembly
 Caser and uncaser overhauling
 Cooling plant overhauling.
Engineering Methods, Tools And Techniques
Methods:
problem solving
 data collection
data analyzing
Interpretation of data

Tools:
extractor to extract bearings, gears
welding machines
grinders
pipe wrench
Allen key set
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.
Measures Taken To Overcome the Challenge:
Working hardly beyond the specified working time.
Doing every task even if it is not concerned us.
Giving positive suggestion and friendly commenting the
tasks.
Gains from internship:
In Terms Of Improving Team
Playing Skills

In Terms Of Improving
Entrepreneurship Skills

In Terms Of Improving Industrial

Problem Solving Capacity

In Terms Of Improving Theoretical

Knowledge

In Terms Of Improving Practical

Skills
Recommendation:
. 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.
.The company must have a well-organized document for coming
internship students how to work, when to work, what to work and who
will be the responsible to advise them.
.The company is that to change its poor advertisement in media about
their works. Although the company has its own website, it is not
sufficient to advertise all the works of the company.

Finally, this Dashen brewery S.C. has shortage of like internet

access or have one computer only in a division and haven’t reference
books for improving knowledge’s of the staff.
Part Two:
Project: Boiler Blow Down Heat Recovery System Design
Introduction:
 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 .
 Project Summary:
 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.
Con…
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.
Problem Statement:
There is a 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 exchancher.
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.
Specific objective:
 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
Methodology
Identifying The Problem

Collection Of Data

Material Selection

Design Analysis

Preparation of Working
Drawing
Design analysis:
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
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.
Con…
we need a storage tank to supply a constant supply of hot water to the heat
exchanger due to two reasons. These are
when during bottom blowing down, hence 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.
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.
Diagrammatically:
Hot Water Storage Tank Design:
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.
 Result:
drawing quantity Dimension Name Material

1 1940mmx681 shell Stainless steel

mm

2 Dia 681mm head Stainless steel

1360mmx30m leg Stainless steel

3 m
Heat Exchanger Design:
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.
.

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.
Piping Design:
 The pipe may have elbows, valves, gates etc. So the equivalent length and
pressure drop is calculated Optimum Pipe Diameter: The capital cost of a
pipe run increases with diameter, whereas the pumping costs decrease with
increasing diameter.
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.
Discussion:

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.
Recommendation:
There is highly energy loss in work kettle and bad noise in the
environment but it does not affect even if it need to recover (recycle)
that heat loss (energy loss).
The boiler operator should take the mandate to control it after being
installed and the servo meters must be checked regularly.
Conclusion:
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 costy 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. So
installing the heat recovery system is economical.
The project also paves the way to other boiler efficiency
improvement options. It is also attractive than any other heat
recovery systems when seen from the length of pay pack period.
.
THANK YOU FOR
YOUR ATTENTION…