Gizachew Endale

Design of Steam Condenser
Mekelle university, Mechanical Engineering Department

By:- Gizachew Endale
MEKELLE UNIVERSITY
ETHIOPIAN INSTITUTE OF TECHNOLOGY-MEKELLE
DEPARTMENT OF MECHANICAL ENGINEERING
INTERNSHIP AND PROJECT REPORT
PREPERD BY:- GIZACHEW ENDALE

ADVISORS: - INSTRUCTOR ABDUL BARIK
COMPANY SUPERVISOR :-MR.DERRA BEZU
OCTOBER, 2013
MEKELLE, ETHIOPIA
Steam condenser
Prepared by - Gizachew Endale
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Acknowledgment
I would like to thank all concerned bodies in the internship program, Industry University
Linkage of Mekelle University, Ayka Addis Textile &InvestmeentGroub, and the Department
Of Mechanical Engineering. Also from the beginning to the end that help me to correct my
faults and to solve my problems many people were in my side especially Ins Abdulbari ,my
advisor and EngrDerra company supervisor and my work mates Suraphelkassahun and
Yishakaberaham. I Thank you very much.
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Abstract
This internship report is on a four month regular program on a company near Addis
Ababa, Alemgena called AYKA ADDIS TEXTIE& INVESTMENT GROUP (AATIG). This report
includes my work experience and design project, which aimed to solve specified problem
on the company. In this project I try to solve the problem on the process of exhausting
steam in steam pipes after steam used in different machines, heat exchangers and steam
bypass that found in dying department of the company.
This project is mainly concerned with solving the problem of damage of steamexhausting
pipes due to the condensation of steam in the pipe and recovering the heat of the released
steam to heat water. Since the steam which is used in different dye process loses its high
pressure property condensation occurs in the steam exhausting pipes. This condensation of
steam in exhausting pipe results in hammering and damage of pipes.
This design of steam condenser work by means of circulating cold water in a tube,
to fully condense the steam in container shell . The wet steam which outs from dye
machines, heat exchangers and steam bypass directed to the container . So that the wet
steam will be condense fully and is easy to exhaust the fully condense steam (condensate)
from the factory.
The circulating water absorbs heat from steam so that it become heated, the
heated water pumped to the preheater of the boiler, so that it become a good source of
pure feed water to the boiler.
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List of tables
i. Table of properties of saturated water (liquid-vapour) pressre

table
ii. Table of properties of superheated water vapour
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Table of content page

Chapter one background of the company
1.1. Brief history of the company................................................................................................1

1.2. Main reasons for the establishment of company..........................................................1
1.3. The raw materials for the company...................................................................................1
1.4. The Main products and services ..........................................................................................2
1.5. The main customer of the company....................................................................................2
1.6. The overall organization and work flow.........2
Chapter two Overall internship experience
2.1. In which section of the company you have been working in......3
2.2. How does the work flow in the section look like 7
2.3. Work task i have been executing.............................................................8
2.4. Challenges I have been facing in performing work task9
2.5. Measure taken to overcome the challenges..........................................................9
2.6. Finding of problems ............................................................................ .................. .................9
Chapter three Project on steam condenser

3.1. Short summery of the project.....................11
3.2. Problem statement and justification...11
3.3. Objective of the project11
3.4. Literature review.12
3.5. Analysis and Design of components
3.5.1. Design of tube....13
i. Calculation for the number of tubes(Nt )..14
ii. Calculation of steam quality entering the condenser15
iii. Calculation for the amount of energy released from steam (Qre).17
iv. Calculation of log mean temperature difference (LMTD)...18
v. calculation of Heat transfer area of the tube(A)...19
vi. Calculation for condensate final temperature of cooling water ( )20
vii. Calculation for condensate film temperature of steam ( )21
viii. Calculation for overall heat transfer of the condenser (Ucal)..23
ix. Calculation for the total length of cooling water tube(L)....25
x. Calculation for Length of one tube27
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xi. Selection for baffles28

3.5.2. Design of container shell
i. Calculation for the height of container.29
ii. Calculation for the width of container..30
iii. Calculation for the length of container.30
iv. calculation for The total surface area of the container...31
3.5.3. Design of pump
i. Selection of pump......32
ii. Calculation for velocity flow33
iii. Calculation for actual or monomeric head (Ha).33
iv. calculation for the fluid power developed by pump (P)35
v. Calculation of power needed to drive the pump (Pmotor)...36
vi. Efficiency of the pump36
3.5.4. Motor selection to drive the pump......................36
3.6) Results and discussion. .....................................37
Chapter four Overall benefit i gained from the internship
4.1. Upgrading theoretical knowledge38

4.2. Improving practical skills..38
4.3. Improving industrial problem solving capability38
4.4. Improving team playing skills..39
4.5. Improving leadership skills...39
4.6. Understanding about work ethics issues..39
4.7. Entrepreneurship skills40
Chapter five Conclusion and recommendation
5.1. Conclusion41
5.2. Recommendation.42
References...43
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Chapter one
Background of the company
1.1 Brief history of Ayka Addis Textile & Investment Group
Ayka Addis Textile and Investment Group (AATIG) is an integrated textile
factory placed in Addis Ababa specifically in Alem Gena 20km far from Addis Ababa. The
company is owned by two Turkish investors and also the name AYKA comes from the
name of the owners of the company, YESUF AYDENZI and GURCAY KAVLAKI.
The Company starts construction in 2006 and starts production in 2009 by

opening the spinning department for manufacturing of yarn. The total integrated
production which includes spinning, knitting, dyeing and garment start in 2010.
AATIG works for 24hr with three shifts, it has 7,000 employees which include
15Turkey, 18 Trilanca and 1 Thailand employees. AATIG is one of the modern and
productive textile factories in Ethiopia, even in East Africa.
1.2 Main reasons for the establishment of AATIG in Ethiopia

Due to cheap labor resource
Due to easy access of raw materials, especially cotton
Due to suitable condition for investment, tax free importing of factory
equipments.
Current capabilities of AATIG
fabricating different yarns

manufacturing of different types of fabrics
dyeing of textiles
Garment and export its product of textiles, yarn, cloths.
1.3 The Raw materials for the company

The raw materials for the company are different type of fibers such as cotton, viscose
and polyester fiber.
The raw materials which get from Ethiopia are:-
Cotton -from Middle Awash
The raw materials which are imported are:-
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Viscose-from Thailand
Polyester-from India, china
Modal, Wool, blonds of the fibers
Viscose rayon-from china, turkey
1.4 The main products and services of the company
Most of the products at AATIG are textiles of different types. These include:-
Yarn
Fabric
Clothes (pajamas, t-shirt, sportswear, underwears)
1.5 The main customer of the company
The main customer of AATIG is purchases products for Europe especially for
Germany & Turkish, the main customers are Tchibo-German which is the main distributor
in Germany.
1.6 The overall organization and work flow
The factory consists of 4 departments spinning, Knitting, Dyeing and Garment. The
work flow start from the Spinning and pass through Knitting, Dyeing and finally to
Garment.
1st step raw materials receiving
The main raw materials for factory cotton received in the knitting section of the factory
and processed and become yarn.
2nd step integrated production
The integrated production starts in the spinning department where the raw material
receiving cotton processed to yarn, and then the yarn transferred to knitting section where
it processed and become a fabric. The fabric manufactured in the knitting section and the
cotton manufactured in the spinning department will dyed (colored) in the dyeing section
of the factory. Then the fabrics will be garmented for different orders in the garment
section.
3rd step marketing
The textiles manufactured will be exported to the main distributors in Europe.
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Chapter two
Overall internship Experience
2.1. Overall process taken in company
In AATIG, there are four departments
i. SPINNING DEPARTMENT
ii. KNITTING DEPARTMENT
iii. DYEING DEPARTMENT / BOYAIYAN
iv. GARMENT
I was working in the dyeing department where coloring or dyeing of fabrics and cotton are
done.
i. Spinning department
The raw material for Spinning room is cotton, the total work flow is as the following order
raw material receiving Cotton

blow room-for opening clearing and mixing of cotton
carding for elimination of short fiber, carding formation
1st drawing for avoiding waste
combing for combining lab
2nd drawing- for controlling silver thick
ring spinning- Twisting the fiber strand to impart strength to yarn, Winding the
resulting yarn
The final yarn manufactured processed to knitting department or to the dying department
(for coloring or dyeing the yarn).
There are different machines that are used in fabricating yarn from the receiving cotton.
Products of spinning
The product of Spinning is yarn, before 3 years ago this yarn was simply packed and
exported to Germany. But now days since the factory start an integrated production this
yarn will be further processed in knitting department.
The spinning section has a capacity of producing 15-20tons of yarn per day.
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ii. Knitting department

The raw material for knitting process is yarn received from Spinning room. the total work
flow is as the following order:-
the receiving yarn transfer to creel
quality check and transfer
knitting
roll fabric (weighing) and roll making
inspection and numbering
In Ayka Addis Textile and Investment Group there are circular and flat knitting machines.
They produce different design type of fabric such as:- plain, rip, inter lock, purl, single
jersey.
There is also a laboratory to test the knitting fabric thickness and thinness, If the fabric is
thick or thin then corrected by changing the loop length either elongate or shorting by
using the corrector.
Generally the knitting department has a capacity of produce 25,000 to 40,000kg of

fabric in a day if there is order.
iii. Dyeing department

Dyeing is a process of applying color to the fabric, to the yarn, to the cotton
The raw materials for dyeing department are fabric from knitting department, yarn from
spinning department and cotton(before it enters spinning department). In this department
the following process are taken:-
Grey fabric inspection-cropping-brushing-singing-desizing-scouring-bleaching-
souring-washing- drying-mercerizing-dyeing
After treatment-finishing-inspection-packing-boiling-delivery to cutting section
Printing
yarn dyeing that is before knitting
cotton dyeing that is before the cotton enter Spinning
In AATIG there are different types of modern dyeing machines for dyeing of cotton, yarn
and fabric
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Jet dyeing machine:- used for dye the fabric by using pressure to rotate the fabric. The size
of the machines are different, it means start from 50kg to 900kg fabric bye in one time.
Winch dyeing machine:-used for dye the fabric by using roller friction to rotate the fabric.
Fig ) winch dyeing machine

Rum machine:-used for fixation, dry, and softening of fabric.
Bruckner machine:-used for drying of fabric:-
Fig) bruckner machine
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Singing machine: - used to remove heavy part of the fabric
Sanford/Ironing machine:-for ironing the fabric.
Erobatech machine: - This machine found in Ayka Addis only in Africa because it is very
coasty. The machine used for all pre-treatment of fabric in a continues process.
Fig) Erobatech machine
There are also some special machines in dyeing department for Eg printing, automation
PRINTING
Printing is a method of putting from simple to complicated designs on the fabric for better
appearance. This design is made by using adobe photo shop C53 soften ware.
There are different types of printing:-
Pigment printing:- usually used to polyester fabric

Reactive printing:- used for cotton fabric by using different chemical
Acid printing:- used for alylon fabric
Disperse print:-used for polyester and cotton fabric
AUTOMATION
the automation is a robot for dosing a different chemical to the bleaching machine or area
on the reserve tank then in the bleaching machine by the order amount.
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Each reserves tankers have the pipe that connected with the color dos machine or
automation
The dyeing department has a capacity of dyeing 50ton of fabrics per day.
iv. Garment department

In the garment department the fabrics and textiles are garmented. This is where the
finishing process of the total factory is done.
2.2. Work flow in dyeing department

This is the department where I have been working most of the internship period.
In dyeing department the following process are taken:-
Scouring - Is one of the process that in order to remove the impurities, oil and fat
that found on the fiber, yarn and fabric. The oil removed by adding caustic soda
(NaOH) by forms saponification.
Bleaching - is a process to produce white yarn and fabric by removing the matter or
impurities with using bleaching agent
Washing - The fabric passing all the above process, It must be washed because to
remove the rest of acid and unnecessary color by using different chemicals.
Softening - After the fabric wash, it will be softened to make the fabric more pleasing
when touch.
After the above process the fabric is squeezed by using centrifugal machines. This squeezed
fabric passes in to drying machine thus drying machine used for drying stretching and
fixing the fabric by using steam and temperature. After fixing the fabric it passes in to the
sanforizing or ironing to remove the wringing part, and then the fabric packed and goes to
the garment.
In addition to the dyeing department I was also spent some time on the following section
Boiler (cazan)
Waste water treatment
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BOILER (CAZAN)
The factory uses excessive steam for different purposes in addition almost all
machines in the dyeing department uses steam for processing. For thus requirements of
steam the factory uses two boilers for steam generating:-
1) coal boiler :- uses coal for producing high temperature in order to heat water and
generate steam. The coal is crushed is by crusher and then burned to boil the water,
the water pipes is directed through burned coal in the boiler furnace so that steam
generated
2) fuel boiler- uses fuel for producing high temperature in order to heat water and
generate steam. A boiler incorporates a fire box or furnace in order to burn a fuel
and generate heat. The generated heat transferred to water to make steam.
In both boilers the water is preheated to some temperature at preheater before the water
enters to the boilers. Finally the steam generated from the two boilers is transferred to a
steam receiver tank then to the factory.
WASTE WATER TREATMENT

In the dyeing department different wastes are drained it contains chemicals
that are hazard for the environment and the sounding pollution. For this reason the
company has waste treating tank.
Waste treating means remove the precipitate chemical by adding neutralizer. In Ayka Addis
textile and investment group mostly use Alkaline and also use some acids, to treat those
lifting acid in the waste.
There is biological erosion tank which has capacity about 2800m3used for developing
bacteria. This bacterium feeds the heavy metal found in the waste. Oxygen is added in the
biological tank for two reasons. To oxidizing the heavy metals bacteria developed. After
the bacteria develop they move in to the segmentation of the tank to segment heavy metal
and to neutralize the water.
2.3. Work task i have been executing

Throughout the internship period i have been exercising different works. I was working
mostly maintenance of dye machines and coal boiler. In addition I participate in assembly
and installation of new dye machines.
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Maintenance of dye machines:-in the dyeing department there are different dye
machines. This machines use high amount of water and steam for process of dyeing
(coloring) of fabrics.
Maintenance of dye machines include changing of valves, changing of steam pipes,

changing of water tubes.
Assembly of new dye machines: - i also got chance to be part of in this process in
assembly of new machines.
Coal Boiler maintenance:-in my time of internship the coal boiler of the factory has faced
some problems relating to bag filter of the boiler.
Participating in the above works I learned what a factory environment looks like. I have
also gained theoretical knowledge, practical skills and interpersonal communication skills.
2.4. Challenges that I face in performing work task

i. The main challenge that I face in performing work task is language problem. The
factory has many Turkish employees in dyeing department who cannot speak
English language including dyeing machine shop head.
ii. In the section that I spent the internship dyeing department there is a safety
problem. Since the machines use chemicals for dyeing, these chemicals are very
dangerous to heath.
2.5. Measures taken to overcome the challenges
The language problem go for a while but after some time I tried to speak some factory
words machine parts like pump, valve, motor in Turkish. So that I start communicating
with Turkish workers and made my connection smooth with the technical manager of the
dyeing department and the head of machine shop.
To solve the safety problem I tried to ask safety shoes and work clothes but they are not
willing to give me. However I overcome the challenge by preparing work cloths in my own.
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2.6. Finding of problems
Throughout the internship period I found some problems related with my knowledge of
Mechanical engineering, especially in area of thermal engineering.
The problems are on the following areas:-
1) Problem of the raw material store

2) problem of heat losing in coal boiler
3) the big problem on steam exhausting system
1) Problem of the raw material store
The raw material cotton is naturally sensitive to moisture of the environment. The
factory stored the cotton in store at moisture content of 3.8%.but the standard of cotton
fiber moisture content is 7-8.5%.since the store is made up of metal and the is no air
conditioning system on store the cotton loss its moisture. this results in decreasing of the
quality of cotton.
The sequence of this kind of storing system will lead to the following problems:-
Decrease fiber strength, increasing of short fiber, Increase the roller loping
The solution for above problem is :-
One by keeping the store from external environmental influence, by making

insulation to the wall of the store or the room.
Or using air conditioner to control the temperature and moisture of the store.
2) Problem of heat losing in coal boiler

The seam available from the boiler is mostly at pressure of 9 bar and temperature of
190c, but when the boiler works for longtime without rest the level inside the boiler goes
down, the pressure of steam increase immediately and steam with pressure above 12 bar is
not needed in the process of the factory.so the steam released to the atmosphere.
The solution for above problem is:-
The released steam have high temperature so that we can reuse by condensation
using steam condenser
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3) Problem on steam exhausting system on the dyeing department

This is the selected problem to which the internship project is done
Chapter three
Project on steam condenser
3.1. Short summary of the project
This project is done on designing steam condenser. The steam condenser is
designed to fully condense the steam which outs from the machines, heat exchangers and
steam bypass of dyeing department.
This steam condenser condensate the exhaust steam by means of circulating cold
water in the tube and receive exhausted steam from machines in the shell. So that the
steam transfer its heat energy to the circulating cold water and become fully condense and
drained.
Since the circulating cold water in tube absorbs heat from steam it become heated
and pumped to the boiler feed system or preheater so that it becomes a good source of
water.
3.2. Problem statement and justification

In the dyeing department steam after processing in different process in dye
machines, heat exchangers, steam bypass exhausted by using steam exhausting pipes,
however there is a frequent damage of these steam exhausting pipes due to the happening
of hammering which is caused by steam condensation in steam exhausting pipes.
When steam condenses in the exhausting pipes of steam there is a mix of hot steam
and wet steam in the pipes which results in hammering. Due to this hammering damage of
steam exhausting pipes and parts of dye machines occur.
3.3. Objective of the project
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The project is aimed to solve the problem of frequent damage of steam exhaust
pipes and parts of dye machines; in addition the design is aimed to recover the heat loss
by the exhausted steam, by designing steam condenser.
The condensate is easily drain from the condenser and the cold water circulated in
the condenser becomes heated and pumped to the preheater of the boiler, that is a great
recovery of the temperature of steam.
3.4. Literature review
The steam condenser in its simple terms is a heat transfer device which reduces a
thermodynamic fluid from its vapor phase to a liquid phase.
There are two principal types of condenser
The jet condenser:-which employs a jet of cold water to condensate

the steam
The surface condenser which employs cold metal surfaces. The
surfaces condenser is used for the majority of steam engine and
steam turbine application
Surface condenser:-
Is the most important type of condenser in present day use. Its main function are to
condense low pressure steam exhausted from turbines or machines.
It has the advantage that the condensate and the cooling water are entirely separate.the
condensate Is then drained and the circulating cold water is heated and pumped to the pre
heater of the boiler.
This type of condenser has a large area of cooling surfaces compared to the system volume,
the steam passes through the condenser and condenses due to contact with the cooling
water.
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3.5) Analysis and design of components
All parts of the steam condenser are well designed carefully in a step by step form. The
steam condenser has 4 main parts:
Tube design for circulating water

Container( shell) design for steam flows
Pump design for pumping water
3.5.1. Design of tube
Design requirements:-
the inlet steam must be contained safely

the condense steam and the cooling water must be safely delivered to
the desired condition
Design analysis
Assumption
1. heat loss due to the environment is negligible

2. no mass is lost from the condenser
3. there is fully developed water flow in tubes
4. there is thermal conduction heat transfer between the motion of the circulating cold
water in tube and the steam on the container shell.
5. the surface of the condenser is adiabatic
6. the inlet temperature of steam entering the condenser Ts=140c
7. the inlet pressure of steam is Ps=1.5bar
8. the convective heat transfer coefficient for
steam=1200w/m2k
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water=2500 w/m2k
Material selection of tube
Stainless steel tube:-
fixed tube plate:-the tubes are fixed with the shell

- Provides max heat transfer area for a given shell and tube diameter
- Less costly than removable bundle designs.
Properties of the stainless steel:- Thermal conductivity of stainless steel k=398w/m
i. Calculation for the number of tubes(Nt )
Assumptions:-
internal diameter of the tube(Di)=5cm

thickness(t)=2.5mm
outer diameter of the tube(Do)=5.5cm
the velocity of cooling water which enters the tube of condenser is V=5m/sec
the volume flow rate of cooling water Qw=0.3m3/sec
The number of stainless steel tube which the water is circulated is calculated from the
discharge formula:- Q=A*V*Nt
Since the discharge of water in the tube Q=A*V*Nt
Where :- Q is volume flow rate of water=0.3m3/sec
Nt is the number of tubes in the condenser
V is velocity of cooling water =5m/sec
A is internal cross-sectional area of tube= A= ,
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Calculating for area (A)= , where Di is inner diameter of the tube =0.05 m
A=
= 0.00196m2
Calculating the number of stainless tubes from the formula of the discharge Q=A*V*Nt
Nt=
Nt=
Nt=30 tubes
ii. Calculation of steam quality entering the condenser(x)
Thermal properties of the steam at inlet pressure (Ps =1.5bar)
From steam table :- at a pressure steam Ps=1.5bar saturated temperature is Tsat=111.4c
Properties of super-heated vapor at Steam pressure( Ps=1.5bar and Tsat=111.4c)
-hf=467.11 sf=1.4386 vf=0.004m3Kg
-hfg=2693.3 sfg=7.2233 vg=59.24m3Kg
Assumption:-
the inlet temperature of steam (Ti=140c)
Calculating for the entropy at (Ps=1.5bar & Ti=140c)
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P=1.5bar &
Tsat=111.4c
Temp S
120 7.2693
140 X
160 7.4665
The entropy X Is calculated by inter pollution 7.3679KJ/Kg so that at p=1.5bar and t=140c
The entropy is s=7.3679KJ/Kgk
Calculating for steam quality(x)
Using the entropy we can calculate quality of steam using a formula S=Sf + xSfg
Where S= entropy at pressure of 1.5 bar and t=140c
= 7.3679KJ/Kgk
Sf= at pressure of p=1.5bar
= 1.4386KJ/Kgk
Sfg= at pressure of water p=1.5bar
= 7.2233KJ/Kgk
Since the entropy is given by S=Sf +XSfg
7.3679=1.4386 + x(7.2233)
The dryness factor of steam X is calculated X= 0.62
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That means the steam is 62% dry and 38% wet
Draw the T-s diagram of the steam condenser
Calculating for vapor pressure of water the vapor pressure of the water is the pressure
which water vapor is in thermodynamic equilibrium with its condensed state
From temperature pressure table at temperature of water (Tw) =15c has vapor pressure
Temp pressure
14 1.6Kpa
15 X
16 1.8Kpa
Calculating for pressure of water at Tw=15c by interpolation the pressure of the water
Pw=0.017Kpa=0.00017bar
Using steam table we can get saturation temperature of steam at a pressure (Ps=1.5bar &
Pw=0.00017bar)
Ts @ Ps=1.5bar=111.40c
Ts @ Pw=0.00017bar=15c
Inlet temperature of steam Ts=140c
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The T S diagram of the system
iii. Calculation for the amount of energy released from steam ( Qre)
Assumption:-
mass flow rate of steam m=3Kg/sec
The enthalpy of steam enters the condenser is given by the formula:-
h2=hf +x hfg
where hf=enthalpy at inlet pressure of steam (p=1.5bar)
hfg= at pressure of(p=1.5bar)
x= the quality of steam =0.62
the enthalpy of steam released
h2=hf + xhfg
=467.11+0.62(2226.5)
h2 = 2290.38
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the overall amount of heat released from steam is given by
Qreleased =m(h2+hf2)
Where m=mass flow rate of steam(assumed m=3Kg/sec)
= 3Kg/sec(2290.38-467.11)
= 6360.69KJ/sec
Qreleased = 6.36MW
iv. Calculation of log mean temperature difference (LMTD)
Assumption
- the coolant inlet temperature in hot tube) t1=15c

- the coolant outlet temperature (outlet of tube)=65c
- the heated water T at outlet of the pump Tsat=65c
- the steam inlet temperature to the shell=140c
- the condensate steam outlet temperature from the shell Tf=40.1c
The log mean temperature difference for condenser is given by
( ) ( )
LMTD= ( )
(( )
)
= ( ) where =Th1-Tc1, =Th2-Tc2

( )
( )
( ) ( )
= ( )
(( ))
)
=4.61c
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Therefor the log mean temperature difference of the condenser LMTD =4.61c =277.61K
v. calculation of Heat transfer area of the tube(A)

Assumption
Fixed tube plate

Tube arrangement square pitch type
Outer diameter of tube Do=0.055
Inner diameter of tube Di=0.05
Log mean temperature correction factor for steam condenser(F)=1
The overall heat transfer coefficient is assumed (Uoass) =600w/m2k
Heat transfer Area of the tube (A)
A=
Calculating for the heat absorbed by cooling water tube (Qw)
Assumption:-
no energy is lost or enter through from the steam condenser container
Since the heat absorbed by circulating cold water is equal to the heat released by the steam
Using energy balance equation
Qreleased by steam=Qabsorbed by water
Since Qreleased by steam=6.36MW= Qabsorbed by water,
Therefor the heat absorbed by circulating cold water is (Qw)= 6.36MW
Heat transfer Area of the tube (A)
A=
where Qw is the heat absorbed by water=6.36MW
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the assumed overall heat transfer coefficient (Uoass) =600w/m2k
LMTD=4.61c=277.61K
Heat transfer area of the tube A=
A =3.82 m2
vi. Calculation for final temperature of cooling water(Ts)
Assumption:-
no energy is lost or enter through from the steam condenser container

mass flow rate of cooling water m=2Kg/sec
the inlet temperature of the cooling water is Ti=15c
the specific heat capacity of the cooling water Cp=4.2KJ/Kgk
By using the formula Qabsorbed by water =mCpt = Qw
we can find the final temperature of the circulated heated water which outs from the
condenser container
Qw =mCpt
Where Qw =6.36MW
m is the mass flow rate of cooling water m=2Kg/sec
Cp is the specific heat capacity of the cooling water Cp=4.2KJ/Kgk=
T=Tf Ti , Ti = inlet T of water (Ti=15c)
Tf=outlet T of water
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Qw = mCp(Tf - Ti )
6.36MW=2Kg/sec*4200KJ/Kgk*( Tf -15c )
Calculating for the final temperature of the heated water (Tf)
Tf= + 15c
Tf=65c
The final temperature of the circulating heated water in the tube which outs from the
system is Tf=65c
vii. Calculation for condensate film temperature of the steam ( )
There are two types of condensation:-
i. Drop wise condensation:-occurred when the steam flows in the tube side of the
condenser and the water circulates in the shell of the container.
ii. Film condensation is occurred when the cold water circulates in the tube and the
stem is in the shell side of condenser.
There is film condensation in this design of steam condenser, the condensate steam
temperature is called film temperature
Assumption :-
the inlet temperature of water Tw=15c

the steam inlet temperature to the shell=140c
Heat transfer coefficient for water hi=2500 W/m2k
heat transfer coefficient for steam ho =1200w/m2k
The final condensate temperature of steam (Tf)
Steam condenser
28
Where Tw=tube wall temperature
( )
Tw= Tc(avg) + ho( )
Tube wall temperature (Tw) is the outside temperature of the water in the wall
( )
Tw= Tc(avg) + ho( )
Where:- =hi*
Tc(avg)= average temperature of the circulating cold water
= 15c
Tu= outlet temperature of the water
= 65c
hio = is the heat transfer coefficient for outside temperature of the wall
= hi *
where hi= Heat transfer coefficient for water =2500 W/m2k
=2500w/m2k *
= 2272.7 w/m2k
The tube wall temperature Tw
Steam condenser
29
( )
Tw= Tc(avg) + ho( )
= 15c + 1200w/m2k ( )
Tw =15.27c
Therefore The final condensate film temperature of the steam will become
Tf2=
Tf2 = 40.1c
Therefor the film condensate temperature is Tf2=40.1c
The condensate steam (Tf2=40.1c) will be drained from the condenser container through
the condensate outlet and drained from the system.
viii ) Calculation for overall heat transfer of the condenser (Ucal)
Assumption:-
Overall heat transfer on inside surface area is equal to heat transfer on outside
surface area
thermal conductivity of the material stainless steel (k=398w/mk )
The fouling factor of steam inside the tube Rfo=0.0001Km2/W
The fouling factor of steam outside the tube Rfo=0.0000877Km2/W
Heat transfer coefficient for steam ho=1200W/m2k
Heat transfer coefficient for water hi=2500 W/m2k
The overall heat transfer coefficient is assumed (Uo ass) =600w/m2k
Steam condenser
30
The overall heat transfer coefficient based on inside and outside surface area of the tube
given by formula
( )
= = + + + +
Where :- Inner surface area of the tube (Ai)= .Di .L
where Di= inner diameter of tube
L= total length of the tube
Outer surface area of the tube (Ao)= .Do . L
Where Di= outer diameter of tube
L= total length of the tube
The overall heat transfer coefficient based on inside and outside surface area of the tube
becomes
( )
= = + + + +
( )
= + + + Rfo +
( )
= + + +0.0000877+
= 0.0013597
Steam condenser
31
The calculated overall heat transfer for outer surface area Uo cal=735.456w/m2k
Check for overall heat transfer
If the design is correct * 100 must be less than 30%
= * 100
=22.57 % < 30%

Therefore, the calculated overall heat transfer co-efficient is well within the design criteria.
ix) Calculation for the total length of cooling water tube(L)
The overall length of cooling water tube is determined from the heat discharge formula
The amount of heat absorbed by cooling water (Qw) is given by
Qw= F .U .A. LMTD
Where Qw =amount of heat absorbed by cooling water
F= correction factor
U=overall heat transfer of the condenser
A= total area of the tube
LMTD= log mean temperature difference
The correction factor(F)
The correction factor (F) is function of capacity ratio (R) and effectiveness (p), F=(P,R)
Steam condenser
32
i. capacity ratio (R)= =
Assumption
The heated water temperature at outlet of the pump is T=65.504c
Since in design of condenser Th1=Th2=65.504c,
Capacity ratio (R) =
=0
ii. the effectiveness (p) is given by
P=
= 0.625
The correction factor for condensers with one shell pass and any multiple of two tube pass
2,4,6,8 etc tube pass is a function P and R,
The number of tubes in this design of steam condenser Nt=30,it is a multiply of 2
There for the correction factor F=F(P,R)
=F(0.625,0)
Steam condenser
33
F =1
Generally for steam condenser the correction factor F=1
Calculating for the total length of the circulating cold water (L)
Assumption:-
Log mean temperature correction factor for steam condenser(F)=1
Using the formula Qabsorbed by water =F*U*A*LMTD
Where area of the tube (A)= dL*Nt
Qw = F*U*A*LMTD
=1*735.4**0.055*L*30*277.61
6.26MW =0.17MW*L
Therefore the total length of cold water tubes that circulates in the condenser (L)=36.2m
x ) Calculation for Length of one tube
Since, The overall length of tubes in the condenser L=36.2m and,
The number of tubes pass Lt=30
Length of one pass tube=
L =1.2m
Therefore the length of one tube pass is 1.2m
Steam condenser
34
fig ) length of one tube
Tube passes
The number of passes is chosen to get the required tube side fluid velocity to obtain greater
heat transfer coefficient, square pitch type is selected
Outer diameter of tube Do=0.055m and Inner diameter of tube Di=0.05m
xi) Selection for baffles
Steam condenser
35
Baffles are used to increase the fluid velocity by diverting the flow across the tube bundle
to obtain higher transfer co-efficient.
The baffle spacing for condenser is B= h (height of container shell).
Steam condenser use a wider baffle spacing of (height of container) as the allowable
pressure drop in shell side vapor is usually less
Baffles are held in positioned by means of baffle spacers. Closer baffle spacing gives greater
transfer co-efficient by inducing higher turbulence. The pressure drop is more with closer
baffle spacing.
Selection of baffles
Vertical cut-segmental baffles are selected for condensers for side-to-side vapor flow
and not for top to bottom, since the steam condenser is horizontal type of condenser.
An opening at the bottom of the baffles is provided to allow draining of condensate.
A baffle cut of 20 to 25% provide a good heat-transfer with the reasonable pressure
drop, The % cut for segmental baffle refers to the cut away height from its diameter.
Steam condenser
36
3.5.2 Design of the container shell

Material selection
The shell for this steam condenser s stainless steel container which thermally from the
outer side to prevent the heat transfer from the steam to the environment
Assumption
- The spacing between the tubes is 6cm

- The length of one tube L=1.2m
- The number of tubes arranged in vertical are 6 tube
- The number of tubes arranged in horizontal is 5 tubes
i. Calculation for the height of container

Height of container=(number of tubes in vertical *Do) +( no of tubes in vertical * spacing)
=(6*0.055m)+(6*0.36m)
=0.69m
For safety adding clearance (10cm) on both side = 2*10cm
=20cm
The total height of container= height of container + clearance
= 0.69m + 0.2m
= 0.89m
ii. Calculation for the width of container

Width of container=(no of tubes in horizontal * Do) + (no of tubes in horizontal * spacing)
= (5*0.055m)+(5*0.06m)
=0.575m
Steam condenser
37
For safety adding clearance (10cm) on both side = 2*10cm
=20cm
The total width of the container =width of container + clearance
=0.575m+0.2m
= 0.775m
iii. Calculation for the length of container

Length of container=length of one tube+clearance
Clearance (10cm) on both side=2*10cm
=20cm
Length of container=length of tube=clearance
=1.2m+0.8m
=1.4m
iv. Calculation for The total surface area of the container

The total Area surface= (2*A1)+(2*A2)+(2*A3)
= (2*L*H)+(2*W*H)+(2*L*W)
= (2*1.4*0.89)+(2*0.775*0.89)+(2*1.4*0.775)
= 2.492m2+1.378m2+2.17m2
= 6.04m2
Steam condenser
38
fig) the steam condenser container
3.5 Design of pump

Pump is used to lift water from a lower level to a higher level at the expense of mechanical
energy. It also increase the pressure energy of a liquid.
Pump convers the mechanical energy into hydraulic energy, the hydraulic energy is in the
form of pressure energy.
i. Selection of pump
In this design of steam condenser I select centrifugal pump to pump out the circulating
water that outs from the system.
Reasons for selection of centrifugal pump
- High efficiency
- Uniform discharge
- Low cost
- Easy in installation and maintenance
- Its coupled directly to an electric motor
ii. Design of centrifugal pumps
Design parameter
Steam condenser
39
This centrifugal pump is connected to the pre-heater of the boiler and the designed steam
condenser with a long stainless steel pipe.
- Length of stainless steel pipe from a steam condenser to the pump (L1=1m)
- Length of stainless steel pipe from a pump to the preheater of boiler (L2=14m)
- The total length of stainless steel pipe (L=L1+L2) is 15m
- Section capacity of the pump (Q=0.02m3/sec)
Assumption
1. Neglect the heat loss due to a gradual enlargement and contractions of pipes
because the pipe diameter is constant.
2. Mechanical loss of pump is 0.3KW
3. The temperature f water enters to the pre-heater of the boiler is Ts=65c
4. The roughness of stainless steel pipe (e=0.46mm)
5. The static head of the pump (Hs=15m)
6. The suction capacity of the pump (Q=0.02m3/sec)
7. The overall efficiency of the pump (overall=85%)
iii. Calculation for velocity flow of heated water (V)

i. from the steam condenser up to the pump (lt=1m)
V1= where Q= volume flow rate of water=0.02m3/sec

A1=Di*L
V1=
( )
V1= 0.01273m/sec
ii. From the pump to the pre-heater of boiler(l2=14m)

V2= where Q= volume flow rate of water=0.02m3/sec
A2=DiL
V2=
( )
V2=0.0011m/sec
Steam condenser
40
iii. Calculation for actual or monometric head (Ha)

the actual or the manometeric head developed by the pump is given by
Ha= Hm= Hs+
=Hs+hf+hl
Where Hs= hs+hd
hs( section head)=1m
hd(delivery head)=14m
hf=(frictional head loss)
hl=other head loss
Calculation for frictional head losses
The head loss due to the roughness of condenser
Since there is a friction loss due to the stainless steel pipe, when the water flows
Hf=
Where f friction factor

L length of pipe from condenser up to the pump=1m
ggravity
D outer diameter
The friction factor (f) is given by f=F(Re , )
stainless steel= 0.046

= =0.00083
Re=
Where at temperature of water (Tw)=65c properties of water
=980Kg/m3
Steam condenser
41
=1.19*10-5Kg/msec
Re=
= 576594
=5.7*105
The friction factor (f) = F(Re , )
= F(57659 ,0.00083)
= 0.00081
Calculating the head loss (hf)=
=
= 0.00095m
Calculating for other head losses (hl)
i. the head due to fitting of stainless steel from the condenser(l=1m)

he head loss for this fitting is given by
hli=
from the table we select the type of fitting for stainless steel pipe is get valve
(1/2 open)
k=4.5
hli=
( )
hli=
hli=0.00371m
ii. the head loss due to fitting of stainless steel from the pump to the preheater of
boiler (l=14m)
Steam condenser
42
hl0=
( )
hl0=
hl0= 0.00252m
the other head loss h1=hli + hlo

= 0.00371m + 0.00252m
h1 = 0.00623m
the manometeric head becomes
Hm= Hs+
= Hs+ hf +
= 15m+0.000095m+0.00623m
Hm= 15.006325m
iv. calculation for the fluid power developed by pump (P)

the fluid power developed by the pump is given by
p=gHmQ
=100Kg/m3 * 9.81m/sec2 * 15.006325m * 0.02m3/sec
= 2.94KW
v. Calculation of power needed to drive the pump (Pmotor)

the power needed to drive the pump becomes
Pmotor=
=
= 3.46KW
vi. Efficiency of the pump
Steam condenser
43
the mechanical efficiency of the pump is given by
m =
where mechanical loss is assumeed = 0.3KW
m
m = 91.3%
3.5.4 Motor selection to drive the pump

Using the power needed to drive the pump (Pmotor) = 3.46KW
Take Pmotor =4KW for safety and I select motor from the standard motor catalog table.
Motor with Pmotor =4KW and rpm=2905 is selected
3.6 Result and Discussion
As I design the parts of steam condenser and pump to pump the circulated heated water to
the pre heater of the boiler, the motor to drive the pump selected from standard.
the three dimensional view of the steam condenser is designed in catia software
Steam condenser
44
The inlet of the circulating water is at the top of the container
The inlet of steam is at side of the container
The condensate drained at the bottom
The circulating heated water pumped to the pre heater of the boiler by the pump
Steam condenser
45
Chapter four
Overall benefits of the internship program
Overall benefit gained from intern ship
As I have seen the different departments of the company I up grade my practical
skills by working with the company workers and engineers. Especially in the dyeing
department and boiler section where I spent most of the internship period
4.1. Upgrading Theoretical knowledge

Knowledge is mainly based on theory, thus it was necessary by any means to
change or interpret the theoretical knowledge to practical one. My internship period in
AATIG was very helpful in up grading my theoretical knowledge.
The knowledge I had on how heat exchangers work the pneumatic system of air and on air
conditioning of rooms, was now very much clear to understand and maintain by relating to
the theoretical knowledge.
The following theoretical knowledges are upgraded in the time of internship:-
knowledge on heat exchangers

knowledge on pneumatic systems
knowledge on air conditioning system
Further knowledge on machine parts, machine operations, system of machines.
4.2. Improving Practical skills

As I have spent 4 months in AATIG, since practice makes perfect through time I improve
my practical skills especially in maintenance of machines, boiler system of the factory.
I also improve practical skills in the following work areas:-
machine installation and assembly of machines

Maintenance rooms of dyeing department
Wastewater treatment
4.3. Improving Problem solving capacity
Steam condenser
46
I improve my problem solving capacity in different problems of the factory,

especially in the dyeing department of AATIG, there are different problems relating to
steam system which I tried to solve by this project, which aimed to solve the great problem
on damage of steam exhausting pipes and hammering.
Self confidence
Risk taker
Hard work
creativity
4.4. Improving team playing skills

During my internship period in AATIG; I was able to work with new employees,
especially in the dyeing department in maintenance of machines, heat exchangers and
installation of new machines.
At that time of periods they have been appreciating my effort and idea that I had
been bringing as a solution for the problem of steam exhausting system and I fully believe
that the internship has made me improve my team playing skills.
Peaceful communication with workers

Knowledge sharing with workers
I Develop capability of team working
Learning Turkish language to communicate with Turkish engineers
4.5. Improving leadership skill
In AATIG there are 4 maintenance rooms KNITTING,SPINNING,DYEING AND
GARMENT maintenance rooms for each department, providing maintenance and
installation of machines. These maintenance rooms need safe management system to
increase the work ability and productivity.
In the duration of my internship I have learn different idea of leadership skills that I will
improve my leadership skill for the future. Some they are:
How to organize different work division
Taking responsibility in every direction of work flow,
Give respect for every worker,
Problem solving ability
How to make free discussions with works,
Steam condenser
47
Equally treat any workers without discrimination
4.6. Understanding Work ethics issue

Work ethics related issue is the behaviors of doing work with good conduct without
discrimination of others, in everything on the work place. Work ethics is main point for
successful achievement of work.
Work ethics include:-
Punctuality
Motivation and commitment for work
Respecting other work
Thanks for the company workers that they flow their all efforts to show how it is
done from maintenance of machines up to installation of new machines.
4.7. Entrepreneurship skills

As mechanical engineering, Entrepreneurship is creating a new way of system to improve
something old or creating new one which aimed to make money. Being an entrepreneur
has benefit for achievement of economic development by using different resources.
An entrepreneur must have the following abilities or skill:-

creativity
Self confidence
Risk taker
Knowledge of the thing you want to do
Hard work
In the duration of my internship period: I have met many professional, technician,
mechanical engineers, industrial engineers etc. that thought me many important things that
will help me for the future.
Steam condenser
48
CHAPTER FIVE
Conclusion and recommendation
5.1 Conclusion
It is a great experience and learning in the company as it is discussed all
above. The factory has a skilled man power and great capability of manufacturing
integrated production of textiles. The factory has a great roll in introducing modern
technologies for our country. And it is appreciated that it gives many vacancy opportunity
for people. Since the factory compute with world market it is productive and effective in
producing quality fabrics. From the four month regular day training I deeply understand
the factory environment, work flow and overall work organization of the factory.
Steam condenser
49
5.2 Recommendation
I recommended that the factory have to use the resource of water and
steam properly so that there will be no loss, especially in the dyeing department. the
factory must give health insurance to the employees, since the dyeing machines processed
different chemicals which are hazard for health .In order to be more profitable the factory
must keep the right of the workers and should also rise the salary of the workers so that
there will be motivation and commitment for more work.
Steam condenser
50
Reference
1. Fundamentals of Engineering Thermodynamics. Michael J.Moran & Howard
N.Shapiro, 5th edition
2. Specification for Shell and Tube Type Heat Exchangers, BIS 2007, New Delhi.
3. D. Q. Kern, Process Heat Transfer, McGraw-Hill Book Company
Steam condenser
51

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Design of Steam Condenser

Mekelle university, Mechanical Engineering Department

DEPARTMENT OF MECHANICAL ENGINEERING

INTERNSHIP AND PROJECT REPORT

PREPERD BY:- GIZACHEW ENDALE

COMPANY SUPERVISOR :-MR.DERRA BEZU

i. Table of properties of saturated water (liquid-vapour) pressre

ii. Table of properties of superheated water vapour

Table of content page

1.1. Brief history of the company................................................................................................1

Chapter two Overall internship experience

Chapter three Project on steam condenser

xi. Selection for baffles28

3.6) Results and discussion. .....................................37

Chapter four Overall benefit i gained from the internship

4.1. Upgrading theoretical knowledge38

Chapter five Conclusion and recommendation

The Company starts construction in 2006 and starts production in 2009 by

1.2 Main reasons for the establishment of AATIG in Ethiopia

Current capabilities of AATIG

fabricating different yarns

1.3 The Raw materials for the company

The raw materials which get from Ethiopia are:-

Cotton -from Middle Awash

The raw materials which are imported are:-

raw material receiving Cotton

ii. Knitting department

Generally the knitting department has a capacity of produce 25,000 to 40,000kg of

iii. Dyeing department

Fig ) winch dyeing machine

Bruckner machine:-used for drying of fabric:-

Fig) bruckner machine

Singing machine: - used to remove heavy part of the fabric

Sanford/Ironing machine:-for ironing the fabric.

Fig) Erobatech machine

There are different types of printing:-

Pigment printing:- usually used to polyester fabric

iv. Garment department

2.2. Work flow in dyeing department

WASTE WATER TREATMENT

2.3. Work task i have been executing

Maintenance of dye machines include changing of valves, changing of steam pipes,

2.4. Challenges that I face in performing work task

2.6. Finding of problems

The problems are on the following areas:-

1) Problem of the raw material store

The solution for above problem is :-

One by keeping the store from external environmental influence, by making

2) Problem of heat losing in coal boiler

The solution for above problem is:-

3) Problem on steam exhausting system on the dyeing department

3.2. Problem statement and justification

3.3. Objective of the project

3.4. Literature review

There are two principal types of condenser

The jet condenser:-which employs a jet of cold water to condensate

3.5) Analysis and design of components

Tube design for circulating water

3.5.1. Design of tube

the inlet steam must be contained safely

1. heat loss due to the environment is negligible

Material selection of tube

Stainless steel tube:-

Since the discharge of water in the tube Q=AVNt