SMOKES STACKS/ CHIMNEYS

ME_513: I N D U S T R I A L P L A N T E N G I N E E R I N G :
ENGR. GERALD SANQUI ROBLES, MEM

WHAT IS A SMOKES STACK??? A CHIMNEY???

Smoke stacks and chimneys maybe
misinterpreted as one over the other, and most
often than not, smokestacks are referred to also
as chimneys. Though they both serve the very
same purpose, that of providing access point/
exhaust for combustion/ flue gases as a result of
the combustion of fuel (solid, liquid, and gas). SMOKE STACKS CHIMNEYS

Flue/ Combustion Gases being exhausted via a network of

smoke stacks.

These combustion/ flue gases may either come from a boiler (steam
generating unit, SGU), a furnace, a woodstove, or a fireplace.
CHIMNEYS/ SMOKE STACKS
showing their internal space *A “FLUE” is simply a space/ passage for conveying exhaust/ combustion gases to the
termed as a “flue” outdoors/ outside atmosphere. This flue may be a duct, pipe, vent, or chimney.

(1) BOILERS are heat exchangers that are used to convert water into vapor/ SHV (evaporation) by using
the products of combustion as the heating source. Kinds of boilers include FIRE TUBE BOILERS has the
products of
combustion
entering loops of
tubes surrounded
by water while
WATER TUBE
BOILERS has water
passing through
loops of tubes that
are being
(A) BOILER (STEAM GENERATING UNIT); (B) FIRE TUBE BOILER; &
surrounded by (C) WATER TUBE BOILER
products of
combustion.

(2) FURNACE is a piece of equipment that provides fired heat for industrial processes that require
temperatures that exceed 400 °C. Many industrial processes require such heat for the preparation of
materials for
production or for the
completion of an
application/ process.
It is usually composed
of refractory
materials such as
bricks that has very
low thermal
conductivity (ability to

SMOKESTACKS/ CHIMNEYS_MEID 513: Industrial Power Plant by GSROBLES

 transfer heat).
(3) FIREPLACE is a heating unit located in homes/
households to radiate heat coming from the
burning of wood as fuel. It is usually built from
refractory materials such as bricks that has a
very low thermal conductivity.

Since there is only one opening, the heat

of combustion should be concentrated, hence,
the need for a low thermal conductivity kind of
material.

(4) WOODSTOVE is another heating unit located in homes/ households to radiate heat coming from the
burning of wood as fuel except that it
is made-up of steel (a high conductor
of heat). With steel as the material, it
effectively radiates heat from all
parts/ corners of the “stove” and that
it could also be used for cooking
purposes as the name implies.

HOW DO YOU DIFFERENTIATE A SMOKESTACK FROM A

CHIMNEY???
A smokestack differs from a chimney in terms of
the following:
1_Material Composition
2_Shape or Configuration
3_Intended Purpose
SMOKE STACK CHIMNEYS

1_MATERIAL COMPOSITION:
SMOKESTACKS are generally made from steel (carbon steel, stainless steel; alloy piping, etc.) and are
available in four (4) types namely:

1A_SINGLE WALL SMOKESTACKS:

Only has one (1) layer of steel with no
insulation and is normally used for woodstoves/
stove pipes. Maybe in the form of a pipe/ rolled
metal sheet.

SMOKESTACKS/ CHIMNEYS_MEID 513: Industrial Power Plant by GSROBLES

 1B_DOUBLE WALL SMOKESTACKS:
Has two walls/ pipes with insulation in between to vent-
out woodstoves/ stove pipes and fire place. The insulation
keeps the outer pipe from having a higher temperature.

1C_MULTI-FLUE SMOKESTACKS:
Vents out flue/ exhaust gases from one or more sources
into a single smokestack/ chimney structure with an outer
shell. It requires great lengths of piping/ ducting from
sources of flue/ exhaust gases.

*MULTI_FLUE CHIMNEY:
The same concept can also be
applied to households being heated
via a number of fireplace/ wood-
stove venting out smoke into a
clustered single chimney.

1D_CLUSTER SMOKESTACKS:
Similar to multi-flue
smokestacks and are erected in
close proximity with one another
due to site constraints except that
they do not have a common outer
shell. It also requires long piping/
ducting coming from flue/ exhaust
gases sources.

CHIMNEYS meanwhile are made

from refractory materials such as
bricks, clay, stones, cement, etc.
with or without reinforcing bars.
These refractory materials has a
very low thermal conductivity to
effectively make use of the heat
for the heating of occupants.

SMOKESTACKS/ CHIMNEYS_MEID 513: Industrial Power Plant by GSROBLES

2_SHAPE OR CONFIGURATION:
SMOKESTACKS are very tall (around 500ft
or higher) slender structures that typically has a
circular cross-section (basic shape of pipe).
They are more economical and easier to
construct compared to chimneys.

The great heights (around

500ft or more) of smokestacks are
critical so that the discharged
exhaust gases create a “fanning
plume” instead of a “fumigating
plume” which can inundate/ affect
a nearby community which is due
to wind speed quality which vary at
differing elevations. Wind speeds vary at different elevations, it is fastest at the highest point
& vice-versa

On the other hand,

CHIMNEYS normally has a
square/ rectangular cross-
section but at times may also
have a circular cross-section
which are quite difficult to
construct/ assemble in terms
of brick laying and should be
provided with some
reinforcement. Chimneys normally have a squqre or rectangular cross-section but maybe
at times also of a circular cross-section

Erecting chimney structures in roofings

(pitched/ flat) of households should conform to
the “3-2-10ft rule”.
This rule means that your chimney's
shortest side needs to be at least 3 feet above the
roof penetration, and its top has to be 2 feet
higher than any part of the building that's within
10 feet. This is necessary to prevent possible
THE “3-2-10FT RULE OF THUMB” damage of roofing due to the contact of the hot
smoke/ flue gases.

SMOKESTACKS/ CHIMNEYS_MEID 513: Industrial Power Plant by GSROBLES

3_INTENDED PURPOSE:
SMOKESTACKS vents-out exhaust/ flue gases as a result of
the combustion of fuel (solid, liquid, & gases) that might include
nitrogen oxides, sulfur dioxide, carbon dioxide, carbon monoxide,
and other particulate matter “very high” into the atmosphere to
help disperse them safety (so as to limit their impact on air quality
among local communities).

*CONTROL MEANS TO ADDRESS AIR POLLUTION_ELECTRO-STATIC PRECIPITATORS:

To remove
particulate matter from
the gas stream, an
“ELECTRO STATIC
PRECIPITATOR (ESP)” is
used. It uses electrical
energy to charge
particles either
positively or negatively
where they then cling onto collector plates that are oppositely charged. The gas stream is then rid of such
“pollutants” before it is discharge high-up in the atmosphere.

** CONTROL MEANS TO ADDRESS AIR POLLUTION_WET SCRUBBERS:

A “WET SCRUBBER”
mechanism may also be used to
reduce the amount of particulate
matter by employing a spray
manifold system.
As particulate matter is
sprayed with water it increases
its density thereby detaching
itself from the stream of flue
gases.
The less dense flue gases
moves upward while the heavier
wetted particulate matter moves
downward to a collecting bin.

SMOKESTACKS/ CHIMNEYS_MEID 513: Industrial Power Plant by GSROBLES

 WHY DO CERTAIN STACKS HAVE FLARES/ FLAMES BURNING
ATOP???
FLARE STACKS are refinery safety equipment that are
used to manage waste gases (hydrocarbon gases) that cannot
be captured/ processed. As hazards, such waste gases cannot
just be released into the atmosphere, hence, the need for the
burning process.

CHIMNEYS vents-out smoke mainly from

the combustion of burning wood which are
used primarily for heating purposes inside
homes/ houses.
This may come from either a fireplace/
woodstove that is less toxic due to the differing
combustible material (usually coal) being
FIREPLACE WOODSTOVE
burned as compared to those of smokestacks.

IS THE HEIGHT OF A SMOKESTACK/ CHIMNEY CRITICAL???

The height of a smokestack/ chimney, “H”
influences its ability to transfer flue/ exhaust/ flue
gases to the environment via the so called
“STACK/CHIMNEY EFFECT” which technically
eliminates outside air conditions from affecting the
natural air flow movement inside (due to differing
densities).

Again, aside from creating the natural air

flow movement of flue/
exhaust gases, this
smokestack/ chimney
height, “H” is also critical so
that such gases do not
directly interfere with the
atmospheric conditions of
air (as air velocity is greater
at higher elevations).

WHAT ARE THE CLASSIFICATION OF SMOKESTACKS/ CHIMNEYS???

Other than the kind of material to where they are made-up of, SMOKESTACKS/ CHIMNEYS may also be
classified according to the following:
1_Classification based on lining

SMOKESTACKS/ CHIMNEYS_MEID 513: Industrial Power Plant by GSROBLES

 1A_With Lining
Chimneys/ smokestacks
are at times provided with
a “lining material” mainly
to extend their life and
prevent these flue/
exhaust gases which are
harmful emissions from
making contact with other
parts of the structure. CHIMNEY WITH LINING SMOKESTACK WITH LINING

1B_Without Lining
Are those that are bare/ do not have any “lining material” as a means of protection/ barrier and
one that has a short useful life against the flue gases which are corrosive by nature.

2_Classification based on structural support

2A_Guyed
Are smokestacks that are provided with tension
cables called a “wire rope” or a “guy wire” to add to its TENSIONER
SUPPORT
vertical stability and prevent its free-fall.
A “guy wire” is a rope that has multiple strands of wire
enabling is flexibility and ability to sustain heavy loads
without snapping.

2B_Self Supporting WIRE ROPES OF

Has a “flared” or “conical” base or wider base which is bolted for its stability. VARYING TYPES
They may also be termed as “cantilever chimneys/ smokestacks”.

FLARED/ CONICAL BASE WHICH ARE BOLTED AGAINST A MACHINE FOUNDATION

WHAT ARE THE FACTORS AFFECTING THE SIZE OF A SMOKESTACK/

CHIMNEY???
The proper sizing of the SMOKESTACK/ CHIMNEY HEIGHT, “H” is directly
affected via the following factors:
1_Volume of flue/ exhaust gases
2_Temperature of the flue/ exhaust gases at the entry point
3_Exit velocity required
4_Composition of the flue/ exhaust gases.

SMOKESTACKS/ CHIMNEYS_MEID 513: Industrial Power Plant by GSROBLES

 FORMULAS:

1_DENSITY OF AIR, ρair:

where:
ρair -- mass density of surrounding air, kg/ m3
Pair -- air pressure or atmospheric pressure or barometric
Pressure; if not given refer to std. reference value at
sea level: 101.325 kPa; 1.0332 kg/ m2
Ra -- gas constant for air, 0.287 kJ/ kg-oK
Ta -- absolute temperature of air, oK
= oC + 273

2_DENSITY OF FLUE/ EXHAUST GASES, ρg:

where:
ρg -- mass density of flue/ exhaust gases, kg/ m3
Pg -- flue/ exhaust gas pressure
refer to air pressure or atmospheric pressure or
barometric; if not given refer to std. value at sea
level: 101.325 kPa; 1.0332 kg/ m2
Tg -- absolute temperature of flue/ exhaust gases, oK
= oC + 273
Rg -- gas constant for flue/ exhaust gases, kJ/ kg-oK
if not given refer to gas constant of air at
0.287 kJ/ kg-oK or refer to the use of Rg = 8.314/
mwg in units of kJ/ kg-oK provided that mwg is
given at 30.

** If gravimetric analyses (% component) of flue/ exhausts gases are cited:

USE R = 8.314 / Ʃ mW gases present

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3_OVER-ALL DRAFT HEAD/ DRAFT PRESSURE, hw:

where:
hw -- over-all draft head/ draft pressure, kg/ m2
= theoretical draft, if no other data is given
= hactual, if no losses are cited
hactual -- actual draft head/ draft pressure, normally in
“m” of water to be changed into kg/ m2 with the “m
of water value” being multiplied via density of
water
(1000 kg/ m3).

4_CHIMNEY/ STACK HEIGHT, H:

where:
H -- chimney/ stack height, m
hw -- over-all draft head/ draft pressure, kg/ m2
ρair -- mass density of air, kg/ m3
ρg -- mass density of flue/ exhaust gases, kg/ m3

5_VOLUME FLOW RATE OF FLUE/ EXHAUST GASES, Ѷg:

where:
Ѷg -- volume flow rate of flue/ exhaust gases, m3/ sec
ṁg -- mass flow rate of flue/ exhaust gases, kg/ min
Rg -- gas constant of flue/ exhaust gases, kJ/ kg- oK
Tg -- absolute temperature of flue/ exhaust gases,oK
= oC + 273

Pg -- pressure of flue/ exhaust gases, kN/ m2

6_THEORETICAL VELOCITY OF FLUE/ EXHAUST GASES, √t:

where:
√t -- theoretical velocity of flue/ exhaust gases, m/ sec
go -- observed gravitational acceleration, if not given use
9.806 m/ s2
hw -- over-all draft head/ draft pressure, kg/ m2
ρg -- mass density of flue/ exhaust gases, kg/ m3

7_ACTUAL VELOCITY OF FLUE/ EXHAUST GASES, √a:

where:
√a -- actual velocity of flue/ exhaust gases,
m/ sec
√t -- theoretical velocity of flue/ exhaust
gases, m/sec

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8_BY MASS BALANCE IN THE FURNACE TO STACK/ CHIMNEY SET-UP:

where:
ṁa -- mass flow rate of air, kg/ min
ṁf -- mass flow rate of fuel (normally coal), kg/ min
ṁash -- mass flow rate of ash (%age of ash loss x coal
used), kg/ min
ṁg -- mass flow rate of flue/ exhaust gases, kg/ min

9_CHIMNEY/ STACK DIAMETER, D:

where:
D -- chimney/ stack diameter, m
Ѷg -- volume flow rate of flue/ exhaust gases, m3/ sec
√a -- actual velocity of flue/ exhaust gases, m/ sec

SAMPLE PROBLEMS:
1. A steam generating unit has an over-all draft loss of 300mm of water. Air enters at 1 atm,
27oC, and the average flue gas temperature is found to be 200oC. What is the necessary
height of stack in meters if no draft fans are to be installed?
A_679m B_697m C_769m D_796m

2. A coal fired steam boiler uses 3000kg of coal per hour. Air required for combustion is 15.5
kg per kg of coal at barometric pressure of 98.2 kPa. The flue gas has a temperature of
285oC and an average molecular weight of 30. Assuming an ash loss of 11% and allowable
gas velocity of 7.5 m/s, find the diameter of the chimney.
A_1.91m B_1.82m C_2.62m D_2.93m

3. The actual draft required for a cupola furnace is 50mm of water plus frictional losses in
the stack at 12% of the theoretical draft. Air enters at 20oC and the average flue gas
temperature was observed to be 137oC. Assuming a molecular weight of 30 for the flue
gas, determine the required stack height in meters.
A_128m B_182m C_236m D_290m

4. In a steam power plant, 3kg of coal is consumed per second and it was later found that
20kg of dry flue gas is produced per kg of coal fired. Air enters at 23oC. The average
temperature of the flue gas entering the chimney is 323oC and the average temperature
of the flue gases inside the chimney is 275oC. A theoretical draft of 4.5cm of water at the
base of the chimney is needed. The gage fluid specific volume is 1.001 Li/ kg. Account for
the chimney diameter in meters.
A_2.83m B_4.13m C_6.71m D_8.01m

5. A power plant is situated at an altitude having an ambient air pressure of 96.53 kPa and
23.88oC. Flue gases at a rate of 5 kg/s enter the stack at 200oC and leaves at 160oC. The
flue gas gravimetric analyses are 18% CO2, 7% O2, and 75% N2. Calculate the diameter of
the stack in meters for a driving pressure of 0.20 kPa.
A_0.75m B_0.85m C_0.95m D_1.15m

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