Industrial Plant

Engineering
By: Engr. Lester Alfred M. Olasiman
Stacks &
Chimneys
Chimney
• A gas passage normally made of
bricks and concrete to expel gases to
the atmosphere.
• Industrial chimneys are commonly
referred to as flue gas stacks and are
generally external structures, as
opposed to those built into the wall
of a building. They are generally
located adjacent to a steam-
generating boiler
or industrial furnace and the gases
are carried to them with ductwork.
Chimney
Function of Chimney
• To dispose the exhaust gases at
suitable height so that no
pollution will occur in the vicinity.
• To produce necessary draft
required for the flow of the
gases.
Types of Chimney
Steel Chimneys are frequently The steel chimneys are of two
known as steel Stacks. The steel types:
chimneys are made of steel plants
and supported on foundation. The 1. Self-supporting steel chimneys
steel chimneys are cylindrical in 2. Guyed steel chimney
shape.
To provide larger base and greater
stability, and to allow for easy
entrance of flue gases, the lower
portion of the steel chimney is
widened or flared out.
Self - Supporting
Steel Chimneys
A self-supporting steel
chimney or stack is made of
steel plates and supported on
foundations. When the lateral
forces (wind or seismic
forces) are transmitted to the
foundation by the cantilever
action of the chimney, then
the chimney is known as self-
supporting.
Self - Supporting
Steel Chimneys
A self-supporting steel
chimney or stack is made of
steel plates and supported on
foundations. When the lateral
forces (wind or seismic
forces) are transmitted to the
foundation by the cantilever
action of the chimney, then
the chimney is known as self-
supporting.
Guyed Steel Chimney
Guyed steel chimneys: In high
steel chimneys, the mild steel wire
ropes or guys are attached to
transmit the lateral forces.
Such steel chimneys are known as
guyed steel chimneys. In guyed
steel chimneys, all the externally
applied loads (wind, seismic force,
etc.) are not totally carried by the
chimney shell.
Formulas
• Density of air & flue gas, 𝜌
𝑃
𝜌𝑔𝑎𝑠 𝑜𝑟 𝑎𝑖𝑟 =
𝑅𝑇
• Volume flow rate of gas, 𝑄𝑔𝑎𝑠
𝑚𝑅𝑇
𝑄𝑔𝑎𝑠 =
𝑃
• Draft Head, ℎ𝑤
ℎ𝑤 = ℎ𝑐 𝜌𝑎𝑖𝑟 − 𝜌𝑔𝑎𝑠 ; ℎ𝑐 - height of chimney
• Theoretical Velocity, 𝑣𝑡
ℎ𝑤
𝑣𝑡 = 2𝑔
ℎ𝑔
Formulas
• Actual velocity of flue gas, 𝑣𝑎
𝑣𝑎 = 30 to 50% of theoretical velocity
• Chimney Diameter
𝑄𝑔 =𝐴 𝑥 𝑣𝑎
Empirical Formula
Draft Head considering the chimney Velocity at chimney considering the
parameters, ℎ𝑤 ℎ𝑐 and temperatures
1 1
15.91𝑃𝑎 ℎ𝑐 −
𝑇𝑎 𝑇𝑔
ℎ𝑤 = 𝑣 = 8.02 ℎ𝑐
𝑇𝑔
−1
𝛾𝑤
𝑇𝑎
ℎ𝑤 - inWG
𝑙𝑏𝑓 ℎ𝑐 - ft
𝛾𝑤 -
𝑓𝑡 3 𝑇𝑎 & 𝑇𝑔 - °R
𝑇𝑎 & 𝑇𝑔 - °R
𝑣 – fps
𝑃𝑎 - inHg
Sample Problem
1. A boiler uses 2500 kg of coal per hour, and air is required for the combustion of 16 kg per kg of
coal. If ash loss is 10%, determine the mass of the gas entering the chimney.
2. The gas density of the chimney is 0.75 kg/m3, and air density is 1.15 kg/𝑚3 . If the driving pressure
is 0.25 Kpa, determine the chimney’s height.
3. The actual velocity of gas entering a chimney is 8 m/sec. The gas temperature is 25°C, and the
pressure is 98 Kpa with a gas constant of 0.287 KJ/kg-°K. Determine the chimney diameter if the
gas mass is 50,000 kg/hr.
4. A coal-fired steam boiler uses 3000 kg of coal per hour. The air required for combustion is 15.5 kg
per kg of coal at a barometric pressure of 98.2 kPa. The flue has a temperature of 285°C and an
average molecular weight of 30.
5. Assuming an ash loss of 11% and an allowable gas velocity of 7.5 m/sec, find the diameter of the
chimney. 15% of the theoretical draft, calculate the required stack height in meters. Assume that
the flue gas has an average temperature of 149°C and a molecular weight of 30. Assume an air
temperature of 21°C.
Problem 1
A coal fired power plant consumes 3000
kg per hour of coal and air required 15.5
kg per kg of coal. Outside air
temperature is at 305K and the average
flue gas temperature entering the
chimney is 616K. The average
temperature of dry flue gas entering is at
260 °C. Density of fluid is at
994.78𝑘𝑔/𝑚3 with theoretical draft of
2.286 cm of water at the base of the
chimney needed if the barometric
pressure is 760 mmHg.
a) Determine the required height of
the chimney. Considering the
molecular weight of dry flue gas is
30 𝑘𝑔𝑚/𝑘𝑔𝑚𝑜𝑙 .
b) Assuming the ash loss of 11% and
allowable gas velocity of 7.5 m/s,
find the diameter of the chimney.
c) Considering Ultimate analysis of coal
in percentage, recompute B C=
78.28, H = 4.98, O = 4.78, N = 1.37, S
= 1.20, A = 6.23, W = 3.16 As
receive, dry basis and combustible
Problem 1
Given: Required:
𝑚𝑓 = 3000 kg/hr a) Height of chimney, H
𝐴 b) Diameter of chimney, D
= 15.5 𝑘𝑔𝑎 /𝑘𝑔𝑐𝑜𝑎𝑙
𝐹
c) Recompute a) and b)
𝑇𝑎 = 305 K
considering ultimate analysis
𝑇𝑔 =260°C +273 = 533 K
ρ = 994.78 𝑘𝑔/𝑚3
𝐻𝑒𝑖𝑔ℎ𝑡= 2.286 cm of water
Pa = 760mmhg or 101.325 kPa
MW = 30 𝑘𝑔𝑚 /𝑘𝑔𝑚𝑜𝑙
Problem 1 - Solution for a) Height of chimney
ℎ𝑤
ℎ𝑤 =H(𝜌𝑎𝑖𝑟 − 𝜌𝑔𝑎𝑠 ) ; H=
(𝜌𝑎𝑖𝑟−𝜌𝑔𝑎𝑠 )
For ρ𝑎𝑖𝑟 ,
P𝑎 101.325 𝑘𝑁/𝑚2 For total draft, ℎ𝑤
𝜌𝑎𝑖𝑟 = = ℎ𝑤 = height x density
R𝑎T𝑎 0.28706𝑘𝑁−𝑚 (305 𝐾)
𝑘𝑔−𝐾
𝝆𝒂𝒊𝒓 = 1.1573 𝑘𝑔/𝒎𝟑 ℎ𝑤 = 0.2286 m (1000 𝑘𝑔/𝑚3 )

𝒉𝒘 = 228.6 𝑘𝑔/𝒎𝟐
For 𝜌𝑔𝑎𝑠 ,
P𝑔
𝜌𝑔𝑎𝑠 = Thus,
R𝑔 T𝑔
𝑅
𝐾𝐽
8.3143𝑘𝑔−𝐾 𝑘𝐽
228.6 𝑘𝑔/𝑚2
R𝑔 = = = 0.277143 H=
𝑀𝑊 30 𝑘𝑔𝑚 /𝑘𝑔𝑚𝑜𝑙 𝑘𝑔−𝐾 (1.17658−0.685939)𝑘𝑔/𝑚3
101.325 𝑘𝑁/𝑚2
𝜌𝑔𝑎𝑠 = 𝑘𝑁−𝑚
0.277143 𝑘𝑔−𝐾 (533 𝐾) H = 484.979 m or 485 m
𝝆𝒈𝒂𝒔 = 0.685939 𝑘𝑔/𝒎𝟑
Problem 1 - Solution for b) Diameter of chimney
Given 11% ash loss and velocity, V= 7.5m/s, For R𝑔 ,
m𝑔 R𝑔 T𝑔 𝜋 𝑘𝐽
𝑉𝑔 = 𝑄𝑔 = ; 𝑄𝑔 = 𝐷2 (𝑉) R𝑔 = 8.3143/30 = 0.277143 𝑘𝑔−𝐾
P𝑔 4
For m𝑔 by mass balance, 𝑚𝑎 +𝑚𝑓 = 𝑚𝑔 + 𝑚𝑎𝑠ℎ Then, 𝑘𝑔 𝑘𝐽
49170 ℎ𝑟 (0.277143𝑘𝑔−𝐾)(533 𝐾)
For m𝒂 , 𝑉𝑔 = 𝑄𝑔 = 𝑘𝑁 3600𝑠𝑒𝑐
𝐴 𝑚𝑎 101.325 2 ( )
= 15.5 𝑘𝑔𝑎 /𝑘𝑔 =
𝑐𝑜𝑎𝑙 3000 𝑘𝑔 3
𝑚 ℎ𝑟
𝐹 𝑐𝑜𝑎𝑙 /ℎ𝑟 𝑉𝑔 = 𝑄𝑔 = 19.9119 𝑚 /s
𝑚𝑎 = 46500 𝑘𝑔𝑎 /hr
For m𝒂𝒔𝒉 ,
m𝑎𝑠ℎ = 0.11 (3000 𝑘𝑔𝑐𝑜𝑎𝑙 /ℎ𝑟) Thus,
𝜋
𝑘𝑔𝑐𝑜𝑎𝑙
m𝑎𝑠ℎ = 330 ℎ𝑟 𝑄𝑔 = 4 𝐷2 (𝑉)
𝜋
For m𝒈 , 19.9119 𝑚3 /s = 4 𝐷2 (7.5 𝑚/𝑠)
46500 + 3000 = m𝑔 + 330
m𝑔 = 49170 kg/hr D = 1.8386 m
Problem 1 - Solution
Solution for c)
Considering ultimate analysis,
As Received Dry Basis Combustible Gas
C 78.28 80.83 86.39 Dry basis
%C, H, O, N, S, A
H 4.98 5.14 5.5
1 − %W
O 4.78 4.94 5.28 Combustible
%C, H, O, N, S
N 1.37 1.42 1.51
1 − %Ash − %W
S 1.20 1.24 1.32
A 6.23 6.43 -
W 3.16 - -
Total 100 100 100
𝐴 𝑂
= 11.5 C + 34.5 (H – ) + 4.3 S
𝐹 8
Problem 1 - Solution
As Received, For R𝑔 ,
A O 𝑘𝐽
= 11.5 C + 34.5 (H – ) + 4.3 S R𝑔 = 8.3143/30 = 0.277143
F 8 𝑘𝑔−𝐾
A Then,
= 10.5658 𝑘𝑔𝑎 /𝑘𝑔𝑐𝑜𝑎𝑙
F 𝑘𝑔 𝑘𝐽
34367.4 (0.277143 )(533 𝐾)
ℎ𝑟 𝑘𝑔−𝐾
Given 11% ash loss and velocity, V= 7.5m/s, 𝑉𝑔 = 𝑄𝑔 = 𝑘𝑁 3600𝑠𝑒𝑐
101.325 2 ( )
m 𝑔 R𝑔 T 𝑔 𝜋 𝑚 ℎ𝑟
𝑉𝑔 = 𝑄𝑔 = P ; 𝑄𝑔 = 4 𝐷2 (𝑉) 𝑉𝑔 = 𝑄𝑔 = 13.91727 𝑚3 /s
𝑔

For m𝑔 by mass balance, 𝑚𝑎 +𝑚𝑓 = 𝑚𝑔 + 𝑚𝑎𝑠ℎ Thus,

𝜋
• For m𝑎 , 𝑄𝑔 = 4 𝐷2 (𝑉)
𝐴 𝑚 𝜋
= 10.5658 𝑘𝑔𝑎 /𝑘𝑔𝑐𝑜𝑎𝑙 = 3000 𝑘𝑔𝑎 13.91727 𝑚3 /s = 4 𝐷2 (7.5 𝑚/𝑠)
𝐹 𝑐𝑜𝑎𝑙 /ℎ𝑟
𝑚𝑎 = 31697.4 𝑘𝑔𝑎 /hr D = 1.537 m
• For m𝑎𝑠ℎ ,
m𝑎𝑠ℎ = 0.11 (3000 𝑘𝑔𝑐𝑜𝑎𝑙 /ℎ𝑟)
m𝑎𝑠ℎ = 330 𝑘𝑔𝑐𝑜𝑎𝑙 /ℎ𝑟
• For m𝑔 ,
31697.4 + 3000 = m𝑔 + 330
m𝑔 = 34367.4 kg/hr
Problem 1 - Solution
Dry Basis, 32727 + 3000 = m𝑔 + 330
A
=
O
11.5 C + 34.5 (H – 8 ) + 4.3 S m𝒈 = 35397 kg/hr
F
A For R𝑔 ,
= 10.909 𝑘𝑔𝑎 /𝑘𝑔𝑐𝑜𝑎𝑙 𝑘𝐽
F R𝑔 = 8.3143/30 = 0.277143 𝑘𝑔−𝐾
Given 11% ash loss and velocity, V= 7.5m/s,
m 𝑔 R𝑔 T 𝑔 𝜋 Then,
𝑉𝑔 = 𝑄𝑔 = P ; 𝑄𝑔 = 4 𝐷2 (𝑉) 𝑘𝑔 𝑘𝐽
𝑔 35397 ℎ𝑟 (0.277143𝑘𝑔−𝐾)(533 𝐾)
𝑉𝑔 = 𝑄𝑔 = 𝑘𝑁 3600𝑠𝑒𝑐
For m𝑔 by mass balance, 𝑚𝑎 +𝑚𝑓 = 𝑚𝑔 + 𝑚𝑎𝑠ℎ 101.325 2 (
𝑚 ℎ𝑟
)
3
• For m𝑎 , 𝑉𝑔 = 𝑄𝑔 = 14.3344 𝑚 /s
𝐴 𝑚
= 10.909 𝑘𝑔𝑎 /𝑘𝑔𝑐𝑜𝑎𝑙 = 3000 𝑘𝑔𝑎 Thus,
𝐹 𝑐𝑜𝑎𝑙 /ℎ𝑟
𝜋
𝒎𝒂 = 32727 𝒌𝒈𝒂 /hr 𝑄𝑔 = 4 𝐷2 (𝑉)
• For m𝑎𝑠ℎ , 𝜋
14.3344 𝑚3 /s = 4 𝐷2 (7.5 𝑚/𝑠)
m𝑎𝑠ℎ = 0.11 (3000 𝑘𝑔𝑐𝑜𝑎𝑙 /ℎ𝑟) D = 1.55996 m
m𝒂𝒔𝒉 = 330 𝒌𝒈𝒄𝒐𝒂𝒍 /𝒉𝒓
• For m𝑔 ,
Problem 1 - Solution
Combustible Basis, 34984.2 + 3000 = m𝑔 + 330
A
=
O
11.5 C + 34.5 (H – 8 ) + 4.3 S m𝒈 = 37654.2 kg/hr
F
A For R𝑔 ,
= 11.6614 𝑘𝑔𝑎 /𝑘𝑔𝑐𝑜𝑎𝑙 𝑘𝐽
F R𝑔 = 8.3143/30 = 0.277143 𝑘𝑔−𝐾
Given 11% ash loss and velocity, V= 7.5m/s,
m 𝑔 R𝑔 T 𝑔 𝜋 Then,
𝑉𝑔 = 𝑄𝑔 = P ; 𝑄𝑔 = 4 𝐷2 (𝑉) 𝑘𝑔 𝑘𝐽
𝑔 37654.2 ℎ𝑟 (0.277143𝑘𝑔−𝐾)(533 𝐾)
𝑉𝑔 = 𝑄𝑔 = 𝑘𝑁 3600𝑠𝑒𝑐
For m𝑔 by mass balance, 𝑚𝑎 +𝑚𝑓 = 𝑚𝑔 + 𝑚𝑎𝑠ℎ 101.325 2 (
𝑚 ℎ𝑟
)
3
• For m𝑎 , 𝑉𝑔 = 𝑄𝑔 = 15.2484 𝑚 /s
𝐴 𝑚
= 11.6614 𝑘𝑔𝑎 /𝑘𝑔𝑐𝑜𝑎𝑙 = 3000 𝑘𝑔𝑎 Thus,
𝐹 𝑐𝑜𝑎𝑙 /ℎ𝑟
𝜋
𝒎𝒂 = 34984.2 𝒌𝒈𝒂 /hr 𝑄𝑔 = 4 𝐷2 (𝑉)
• For m𝑎𝑠ℎ , 𝜋
15.2484 𝑚3 /s = 4 𝐷2 (7.5 𝑚/𝑠)
m𝑎𝑠ℎ = 0.11 (3000 𝑘𝑔𝑐𝑜𝑎𝑙 /ℎ𝑟) D = 1.60893 m
m𝒂𝒔𝒉 = 330 𝒌𝒈𝒄𝒐𝒂𝒍 /𝒉𝒓
• For m𝑔 ,