®

COMPANY

EXCERPTS FROM THERMAL AND CORROSION

ANALYSIS OF CHIMNEY SYSTEMS

A complete study of the most recent data on the corrosion of metals, refractories,
and various chimney linings coupled with a comparative thermal study of ten
chimney systems using a 24”ID model with 40’ of breeching and 100’ of chimney
at 70º F with zero wind velocity and 30º F with 15mph wind velocity. Flue
velocities of 15, 25, 35, and 55 were considered on all cases to show the effect of
flue velocities on thermal characteristics.

The Index of the study demonstrates the subjects covered.

Contact Van-Packer Company for complete details.

Van-Packer Company
P.O. Box 307
302 Mill Street
Buda, Illinois 61314
Phone: 309-895-2311
Toll Free: 888-877-8225
Fax: 309-895-3891

1 ETC#117/2002
INDEX
SECTION Page No.
PREFACE Please read before using this guide 1-111
I. INTRODUCTION 1
II. THE FLUE ENVIRONMENT 1
A. Corrosives and Dew Points 1
B. Sulfuric Acid 2
C. Sulfur Content and Dew Point 2
D. Sulfur Content of Fuel Oils 3
E. Relationship of Concentration of Condensed Sulfuric Acid
To Temperature of Condensing Surface 3
F. Normal Boiling Points for Aqueous Solutions of Sulfuric Acid 4
G. Moisture Absorption of Sulfuric Acid 4
H. Sulfuric Acid Vapors 4
I. Sulfurous Acid and Sulfur Dioxide 4
J. Hydrochloric Acid 5
K. Hydrochloric Acid Vapors 5
L. Acid Smuts 6
M. Water 6
III. CORROSION OF MATERIALS
A. Types of Corrosion Associated with Stainless Steel 6
1. Intergranular Corrosion 6
2. Pitting Corrosion 7
3. Crevice Corrosion 7
B. Passivity of Stainless Steel 7
C. Corrosion of Stainless Steel 7
1. In Sulfuric Acid 7
2. In Hydrochloric Acid 8
3. By Dry Chlorine and Hydrogen Chloride at High Temperatures 9
D. Corrosion of Carbon Steel 9
1. In Sulfuric Acid 9
2. In Hydrochloric Acid 10
E. Refractories 10
F. Acid Bricks 11
G. Polymers 11
H. Modified Silicates 11
I. Foamed Borosilicate Block 12
J. Organic Membranes 12
IV. USE OF ACID RESISTANT MEMBRANES UNDER ACID RESISTANT BUT
PERMEABLE FLUE LININGS 13
V. NEGATIVE AND POSITIVE PRESSURE CHIMNEY SYSTEMS 13
A. Forced Draft Boilers 13
B. Engine Exhaust Systems 13
C. Incineration 14
D. Forced Draft for Improperly Sized Chimneys 14
VI. WET AND DRY SCRUBBERS 14
VII. HOW TO USE THIS DATA 15
VIII. DETERMINING THE ACID DEW POINTS 16
A. Dew Points in Stack Gases 17
IX. THERMAL ANALYSIS 17
A. The Concept 17
B. The Critical Temperatures 18
1. Critical Acid Dew Points for Flue Surfaces 18
2. Critical Metal Temperatures 19
C. Misconceptions 19
D. Chimney Types Studied 20
1. Group 1 Unlined Uninsulated 20
a. Single Wall Steel 20
b. Double Wall Steel “Air Insulated” 20
c. Triple Wall Steel “Air Insulated” 20
E. The System Model 20
F. Tabulations % Loss Mid Flue to Flue Surface 21
G. Comparisons of Chimney Types 22
H. Effects Due to Diameter Changes 24
I. Gradients Through Refractory 25
X. REFERENCES 26

2 ETC#117/2002
 SECTION 1
INTRODUCTION

Chimney corrosion was only a minor problem for the many

years when energy was inexpensive and flue temperatures of
600º F+ were standard. As fuels became more expensive,
heating appliances became more efficient. Unlined,
uninsulated, carbon steel stacks, which had lasted years, now
had short lives. Chimney failures and replacements are
expensive, thus the first thought was to use stainless steel,
unfortunately, and this too was found to fail rapidly, including
the 300 series, even when used with low sulfur No. 2 Fuel Oil.
Stainless steel is good for atmospheric corrosion, however,
cannot resist the condensed flue gas acids.

Large chimneys and stacks were having similar problems.

Refractory and brick lined chimneys, had withstood effluents for
20 years or more, failed as the equipment was changed to
provide greater efficiency. In cases, the chimneys were simply
too large for the new equipment which in turn provided lower
flue gas velocities and greater heat losses, thus lowered flue
surface temperatures. All these features, plus positive
pressures and acid condensation, have caused serious failure.

We have compiled the latest data available covering the nature

of corrodes and the corrosion of metals, refractories, and other
chimney construction materials. This coupled with thermal
analysis comparisons of various chimney systems should allow
designers a better understanding of the problems involved, the
critical areas and the proper selection of construction materials.

3 ETC#117/2002
VAN-PACKER THERMAL ANALYSIS

Project Name: ________________________________________________________________

Location: ____________________________________________________________________

CHIMNEY CONSTRUCTION:

Layers may be steel,

Insulation or an air space
Please note: All Layers
Need not be used.

CHIMNEY DIMENSIONS

Inside Diameter: __________ Inches

Outside Diameter: _________ Inches

INSULATION OR STEEL THICKNESS

Layer 23: __________ Inches

Layer 34: __________ Inches
Layer 45: __________ Inches
Layer 56: __________ Inches (air space)
Layer 67: __________ Inches
Layer 78: __________ Inches

THERMAL CONDUCTIVITY OF INSULATION (BTU-in/Hr.-ºF-Ft2)

AT TWO CORRESPONDING TEMPERATURES (ºF)

Layer 23K1= __________ @ t1= __________ K2= __________ @T2= __________

Layer 34K1= __________ @ t1= __________ K2= __________ @T2= __________
Layer 45K1= __________ @ t1= __________ K2= __________ @T2= __________
Layer 67K1= __________ @ t1= __________ K2= __________ @T2= __________
Layer 78K1= __________ @ t1= __________ K2= __________ @T2= __________

Chimney Height __________ Feet

Breeching Length __________ Feet
Flue Gas Temperature __________ ºF
Ambient Temperature __________ ºF
Flue Gas Velocity __________ fps
Type of Fuel Burned
Gas __________
Oil __________
Coal/Wood __________

4 ETC#117/2002
 B. THE CRITICAL TEMPERATURES

Critical temperatures are those temperatures that signal problems and suggest more detailed
study. This can include resizing or by application of suitable Linings or Coatings or by a change
in insulation. A complete Thermal Analysis is essential to establish where in the system these
critical temperatures are reached.

1. Critical Acid Dew Points For Flue Surfaces ºF

800º F Temperatures above this point induce structural changes that render stainless
steel susceptible to intergranular corrosion. The temperature range is 800º F -
1650º F.

600º F Temperature at which Hydrochloric Acid vapor is corrosive to stainless steel.

480º F The upper temperature limit for stainless steels with fluoride vapors in the flue gas.

400º F The optical maximum dew point of standard fuels assuming all sulfur is converted
to SO3.

320º F Sulfuric Acid dew point of NO. 6 Fuel Oil with 4% Sulfur content.

275º F Sulfuric Acid dew point of No. 2 Fuel Oil with 6% Sulfur content.

140º F Maximum temperatures at which Hydrochloric Acid has been found in chimney
sampling.

120º F Dew point for water, sulfurous and other chimney acids.

2. Critical Metal Temperatures

1200º F The lowest scaling temperature for stainless steels.

800º F Maximum service temperatures for carbon steel with stress reductions. Carbon
steel begins to oxide at 900º F.

550º F Maximum temperature that carbon steel can withstand without reducing strength.
Temperatures above 550º F will require stress reductions. It is not prudent to
design freestanding chimneys when steel temperatures are above 550º F.
Breeching or horizontal runs can be handled easily up to 800º F.

5 ETC#117/2002
D. CHIMNEY TYPES STUDIED

Figure 11
Group I: Unlined Uninsulated Steel

Group II: Insulated Steel

Group III: Refractory Lined Steel

6 ETC#117/2002
 % Loss Mid Flue to Flue Surface at Appliance Outlet
70º F Ambient Zero Wind

Table 3

Single Wall Double & Insulated Refractory Gunnite

Appliance Steel Triple Wall Steel Lined Lined
Outlet
Mid
Flue Flue Flue Flue Flue Flue
fps fps fps fps fps
Degrees F Velocity Velocity Velocity Velocity Velocity

15 55 15 55 15 55 15 55 15 55
300 31 19 22 22 2 1 8 4 14 7
400 35 22 24 24 2 1 8 4 15 8
500 37 25 39 39 2 1 7 4 15 9
1000 35 28 27 27 2 1 N/A N/A N/A N/A
1800 29 28 28 28 1 1 2 2 4 4
2300 28 28 28 28 N/A N/A N/A N/A N/A N/A

% Loss Mid Flue to Flue Surface at Chimney Outlet

70º F Ambient Zero Wind

Table 4

Single Wall Double & Insulated Refractory Gunnite

Appliance Steel Triple Wall Steel Lined Lined
Outlet
Mid
Flue Flue Flue Flue Flue Flue
fps fps fps fps fps
Degrees F Velocity Velocity Velocity Velocity Velocity

15 55 15 55 15 55 15 55 15 55
300 57 39 22 22 2 1 7 4 14 7
400 59 41 24 24 2 1 8 4 15 8
500 59 43 25 25 2 1 8 4 16 9
1000 50 41 26 27 2 1 N/A N/A N/A N/A
1800 N/A N/A 27 28 2 1 4 2 13 6
2300 N/A N/A N/A 28 N/A N/A N/A N/A N/A N/A

7 ETC#117/2002