FIRED HEATER STACK

The purpose of the stack is to create the necessary draft for flue gases to flow properly through the fired heater system
and to dispose of the flue gases.

This must be done without imposing a positive pressure on any part of the fired heater box, since the construction box is
not pressure-tight and flue gases leaking out can cause severe damage to the fired heater casing and structure. Also, flue
gas leakage could seriously injure nearby personnel. Adequate draft is also necessary for natural draft burners, to
inspirate the required combustion air. The hot stack gases must also be discharged at a safe height with respect to
surrounding equipment (towers and other structures).

Since flue gases contain pollutants such as SOx, NOx, and particulates, the stack must be designed to discharge these
gases in a manner that avoids causing a local pollution problem.

Stack height and flue gas exit velocity are important design variables that allow the stack to discharge and disperse
pollutants for the purpose of meeting regulatory emission requirements. Turndown conditions (as well as design
conditions) must be considered, since ground-level concentrations of pollutants from the flue gases are affected by the
flue gas exit velocity.

STACK DESIGN PROCEDURE

BASIS FOR CALCULATIONS

The diameter is usually a function of the quantity of flue gas flowing. Stacks should usually be designed for a velocity of 25
ft/sec (7.6 m/s). Unless details of the stack are known, for design purposes the diameter should be considered uniform for
the entire length. The design specification should state the inside diameter required at the stack exit. The following
considerations may also affect the stack diameter:

Most stack designs should be based on the following information, which should be used unless specifics of the individual
case indicate otherwise.

1. Flue Gas Characteristics - Assume that the molecular weight of the flue gas is 28.84 lb/lb mole (kg/kg mole), the
same as for air. For elevations up to about 1000 ft (300 m) above sea level, the flue gas density is:

2. Temperature Loss in the Stack - Assume the following temperature drops from the fired heater exit to the stack
exit:
Steel Stacks
FLUE GAS PRESSURE VARIATION

The figure below shows the flue gas pressure variation throughout the fired heater. A typical natural draft fired heater
brings in ambient air at atmospheric conditions. The air then drops in pressure
as it passes through the burners.

Throughout the fired heater, the flue gas encounters frictional pressure drops.
As the flue gas travels up the radiant section, it drops in pressure (due to
friction) but also gains pressure from the stack effect due to the buoyancy of
the high temperature flue gases. The net effect is a small pressure drop
through the radiant section.

At the bridgewall section, the furnace should be operating just below

atmospheric pressure, usually denoted by draft. Typical drafts are about 0.10
in. H2O (0.025 kPa). The flue gas will continue to drop in pressure as it passes
through the tube bundles in the convection section, with extended surfaces suffering more pressure losses than bare
surfaces. Again, there is a small stack effect in the convection section. The flue gas also experiences pressure drops as it
encounters changes in the cross-sectional area (entrance and exit to convection section, entrance to stack, damper,
etc.). As the flue gas travels up the stack, it gains pressure from the stack effect provided by the column of buoyant gases
in the stack and also loses pressure due to friction. The net effect is a gain in draft through the stack, allowing the flue
gases to be expelled from the fired heater.

PRESSURE LOSSES AND ALLOWANCES

The following pressure losses and allowances, in in. of water (kPa), should be included in the system pressure drop :

1. Stack Exit
Loss - Use
one velocity
head (K = 1):

2. Friction Loss Calculate this pressure drop (∆P2) by the standard fluid flow calculation procedures
in Stack and In determining the Fanning friction factor f, for use in the pressure drop equation, use a
Ducts - roughness factor of 0.055 in. for internally insulated stacks (from the suggested range of
0.015 to 0.15 in.). For bare steel use 0.002 in.
For calculating pressure drop in a duct of rectangular cross-section, using equations
intended for conduits with circular cross-section, it is necessary to use an equivalent

(“hydraulic") diameter
3. Friction Loss With the damper wide open: ∆P3 = 0.10 in. of water (0.025 kPa)
Across
Damper
4. Additional These pressure drops depend on the ducting and stack arrangement. They include sudden expansions
Losses and contractions, bends, and intersections of flue gas streams. The sum of these additional losses is
designated ∆P4.
5.
a. Sudden Expansion

b. Sudden Contraction
 Bend losses are detailed in Below Figure. For systems where stack height is determined by fired heater
6. Bends draft requirements, assume that miter bends with turning vanes are to be used. Typical turning vanes
should be included in the design specification. For systems where the stack height is set by local (e.g.,
pollution control) requirements, i.e., the available draft exceeds the required draft, assume the use of
rounded bends with Rt / x = 0.5 and no turning vanes.
 Typical intersections of flue gas streams are shown in Below Figure. Note that these losses are in
7. Intersections addition to normal bend and expansion or contraction losses

A full velocity head loss is taken at the stack (or duct) entrance from the breeching to account for a
8. Stack sudden contraction plus a change in direction:
Entrance
Loss

This pressure drop is calculated for each of the different zones (bare tubes, extended surface tubes) in
9. Flue Gas the convection section.
Pressure
Drop through
Convection
Section
 This negative pressure, ∆P7, is required to prevent flue gas from leaking out through the fired heater
10. Negative casing. Use ∆P7 = 0.10 in. of water (0.025 kPa.)
Pressure at
Top of
Radiant
Section
This pressure drops, ∆P8, depends on the design of the burner
11. Pressure
Drop
Through
Secondary
Air Doors of
Natural Draft
Burners

PRESSURE GAINS

The following pressure gains are found in the fired heater. They are caused by the difference between the density of the
hot gases inside the fired heater and that of the ambient air outside the fired heater. The theoretical draft per ft/m of height
(stack effect, SE) may be found below Figure . Be sure to use the Summer Design Air Temperature in determining available
draft.

Radiant
Section

Convection
Section

Stack
STACK HEIGHT

1. Calculations - Balances of pressure gains and losses must be made for natural draft burners and for the stack.
In the design of forced-draft systems, the fan is sized to cover the pressure drop through the burners. It is customary
not to consider the actual draft available at the burner level when sizing the fan.

a. Burners-
Draft available at the burner level = ∆P7 + ∆PR
The actual draft available usually equals or exceeds the requirements of the particular natural draft burner
selected (∆P8). However, if ∆P8 > ∆P7 + ∆PR, consideration should be given to revising the burner selection to one
requiring less draft. Otherwise, additional stack height must be added to cover this deficiency.

b. Stack - The calculated minimum stack height is based on maintaining a negative pressure at the top of the radiant
section (∆P7 = 0.10 in. H2O or 0.025 kPa). As discussed above, additional height must be added if necessary to
provide the required draft at the burner.

2. Specified Stack Height - The final design stack height, based on draft requirements is: