12.
7 Mechanical Engineering Design
Design Temperature
The strength of materials decreases with increasing temperature and so is stainless steel.
The design temperature at which design stress is evaluated should be taken as the
maximum working temperature of the stack. Therefore, design temperature is, 400℃
(Sinnott et al., 2005).
Thermal stress
Thermal stress arises due to the contraction and expansion of stack caused by the hot flue
gas flowing through its flue.
Thermal stress is given by, σt = E∝ΔT, Pa (The Engineering Toolbox, 2016).
where, E = elasticity modulus of stainless steel = 180 × 109 Pa (The Engineering Toolbox,
2016)
∝ = linear thermal expansion coefficient of stainless steel (type 304) = 17.3 × 10-6 m/m℃
(The Engineering Toolbox, 2016)
ΔT = temperature difference in stack = 400-304 = 96o C
Therefore, the thermal stress in the stack, σt =
180 109 17.3 106 96 = 298.9 299 MPa
Primary Stress
Primary stress includes both longitudinal and circumferential stresses. It arises because
of internal pressure generated in the stack.
PD
Longitudinal stress is given by, σ1 = , MPa (Sinnott et al., 2005)
4t
where, P = design pressure of the stack = 122.606 kPa
D = mean (inside) diameter of the stack = 0.94 m
t = thickness of the stack shell = 0.022 m
122606×0.94
Therefore, the longitudinal stress in the stack, σ1 = = 1.31 MPa
4×0.022
PD
The circumferential stress is given by, σ h = , MPa (Sinnott et al., 2005)
2t
where, P = operating pressure of the stack =122.61 kPa
D = mean (outside) diameter of the stack =1.234 m
t = thickness of the stack = 0.022 m
122606×1.234
Therefore, the circumferential stress, σ h = = 3.44 MPa
2×0.022
Weight of shell
The weight of the shell is given by,
Ws = ρsπDtHs, N (The Engineering Toolbox, 2016)
Where, ρs = unit weight of steel = 77.21 kN/m3 (The Engineering Toolbox, 2016)
Hs = height of steel in the stack = 65 m
t = thickness of a steel = 0.022 m
D = outside diameter of stack = 1.234 m
Therefore, the weight of the shell, Ws = 77.21×π×1.234×0.022×65 = 428 kN
Weight of Lining
The weight of lining is given by, WL = ρLπDtHs, N (Punmia, 1998)
Where, ρL = unit weight of lining = 23.6 kN/m3 (traditional ovens, 2016)
HS = height of the stack = 65 m
t = thickness of the lining = 0.125 m
D = outer diameter of the lining = 1.19 m
Therefore, the weight of the lining, WL = 23.6×π×1.19×0.125×65 = 716.9 717 kN
The weight of the stack, W = 428+717 = 1145 kN
The weight of the stack is increased by 5% to account for ladles and steel angles
(Boopathiraja et al., 2016).
Total weight of the stack, WT = 1.05×1145 = 1202.25 1202.3 kN
Loading
The following loads act on the steel
1. Dead load due to self-weight of the stack
2. Weight of lining
3. Wind loads including the static and dynamic effect
Computation of wind moment
The intensity of wind pressure varies with height, and this variation is significant since
the height of the stack is large. The entire height of the stack is divided into 4 portions of
equal height interval of 16.25 m as shown in Fig.2. For each of the sections, the pressure
of the wind is assumed constant, and acting at its mid-height (Punmia, 1998).
Figure 12.2 Segmentation of stack
Wind Load
Basic speed of wind, vb = 35 m/s (Kibi) (Fuachie, 2017).
The assumed height of each segment of the stack is 16.25 m as shown in Fig. 12.2.
Segment 0 – 1
For height = 65 m, diameter = 1.234 m;
Class of structure = C
Design wind velocity, vz = k1k2k3vb, m/s (Gambhir, 2008).
where, k1 = Risk factor = 1
k2 = Terrain category 2 – most common in rural areas = 1.184 (Kumar, 2019).
k3 =Topography factor = 1
vb = Basic speed of wind = 35 m/s
Therefore, the design wind velocity, vz = 1×1×1.184×35 = 41.44 m/s
Design wind pressure is given as, pz = 0.6vz 2 kPa (Gambhir, 2008).
Where vz = design wind velocity = 41.44 m/s
Therefore, the design wind pressure, p z = 0.6× 41.44 = 1030.4 N/mm 2 1.03 kN/m 2
2
Wind force in this segment, P1 = kpz × projected area, kN (Duggal, 2009).
where, pz = design wind pressure = 1.03 kPa
k = shape factor for the stack = 0.7 (Gambhir, 2008).
Therefore, the wind force in this segment, P1 = 0.7×1.03×(16.25×1.234) = 14.46 kN
Segment 1 – 2
For height = 48.75 m, diameter = 1.234 m;
Class of structure = B
Design wind velocity, vz = k1k2k3vb, m/s (Gambhir, 2008).
where, k1 = Risk factor = 1
k2 = terrain category 2 – most common in rural areas = 1.167 (Kumar, 2019).
k3 = Topography factor = 1
vb = Basic speed of wind = 35 m/s
Therefore, the design wind velocity, vz = 1×1.167×1×35 = 40.85 m/s
Design wind pressure is given as, pz = 0.6v z 2 (Gambhir, 2008).
Where vz = design wind velocity = 40.85 m/s
Therefore, the design wind pressure, p 2 = 0.6× 40.85 = 1001.23 N/m 2 = 1.0 kPa
2
Wind force in this segment, P2 = kpz × projected area, kN (Duggal, 2009).
where, pz = design wind pressure = 1.0 kPa
k = shape factor for the stack = 0.7 (Gambhir, 2008)
Therefore, the wind force in this segment, P2 = 0.7×1×16.25×1.234 = 14.04 kN
Segment 2 – 3