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Basic Design Calculations for Flue Gas Stack Design for a Diesel Genset in India

This article will talk about the basic design calculation of flue gas steel stack or
chimney design of a diesel genset.

A flue gas stack or chimney is typically a vertical tubular structure used


for ejecting exhaust flue gas to the atmosphere. You can see the
chimney or flue gas stack in thermal power plants, diesel gensets,
kilns, and many other plants, where gases evolving from the
combustion process need to be exhausted. The design calculation for
flue gas stack varies from application to application. Here in this article
we will discuss the basic design criterion of diesel engine-driven genset
flue gas stacks. See below how to calculate the diameter and height of
the flue gas stack of a diesel genset:

Calculate Flue Gas Stack Height


- Calculate the specific fuel consumption of your diesel genset. Say it is
X kg. Per hour.

- Find out the percentage of sulphur content in the diesel you are
using. Say it is P%.

- Now, you have to calculate the sulphur dioxide (SO2) percentage in


flue gas. Since the atomic weight of SO2 is double the atomic weight of
sulphur, the percentage of the SO2 in flue gas is 2P %.

- The height of the


Rotary tables with torque motors Buy motor driven rotary tables here
flue gas stack (in meters) according to SO2 emission can be calculated
as:

Height (H) = (X*2P)/100…………….Eqn. 1.1

- Now, you have to check out the recommended minimum chimney


height by the Central Pollution Control Board (CPCB). In case the height
calculated from the Eqn. 1.1 is higher than the recommended height
by CPCB then you go ahead with the calculated height or else you have
to stick to the CPCB recommended height.

Calculate Flue Gas Stack Diameter

- Calculate the exhaust gas quantity. Say it is Y kg per hour.

- Select the flue gas velocity you want to keep inside the stack. Say Z
meters per second (Recommended flue gas velocity inside the stack
is 16 to 20 m/sec as per IS: 6533).
- Diameter (in mm) of the flue gas stack can be calculated as:

Diameter (D) = [(4*Y)/ (3.142*Z)]0.5 .......Eqn.1.2

Conclusion

The design of the steel stack or chimney is important from the diesel
genset performance as well as air pollution point of view. While doing
the flue gas steel stack design calculations you should consider the
design formulas and local pollution control norms.

ELECTROCHLORINATION

Desalination plants require huge volumes of seawater for the generation of fresh
water. Seawater contains large amounts of microbiological fluids which, when passed
through the piping system, form biofouling in the inner surface of the pipeline, which
results in the reduction of the flow rate of water without proper chemical treatment.
Chlorine is the most commonly used disinfectant for water treatment applications for
the prevention of biofouling. The chlorine is available in many conventional forms,
but due to various limitations of the conventional methods, the electrochlorinators
that work on the principle of electrolysis are preferred across the globe for seawater
inlet system treatment. The electrochlorinator is a simple machine, which produces
onsite sodium hypochlorite solution by using only seawater as the raw material. The
hypochlorite generated by this unique technology is very safe, environmentally
friendly and economical. The equipment is user friendly and operates automatically
depending on the need. The process involved in the generation of sodium
hypochlorite is a simple electrolysis of seawater. The seawater is made to pass
through the electrolysers, which are fitted with dimensionally stable electrodes. When
DC power is passed through the electrolysers, the exothermic chemical reaction takes
place and sodium chloride in the seawater gets converted into sodium hypochlorite
solution (NaOCl).
Technical Details
Electrochlorination is a chemical process which uses water, common salt and
electricity to produce Sodium Hypochlorite(NaOCl). The brine solution (or sea
water) is made to flow through an electrolyzer cell, where direct current is
passed which leads to Electrolysis. This produces Sodium Hypochlorite
instantaneously which is a strong disinfectant. This is then dosed in water in the
required concentration to disinfect water, or to prevent Algae Formation and Bio
Fouling.

Operating Principle
In the Electrolyser, current is passed through the anode and cathode in the salt
solution, which is a good conductor of electricity, thus electrolysing the sodium
chloride solution.

This results in chlorine (Cl2) gas being produced at the anode, while sodium
hydroxide (NaOH) and hydrogen (H2) gas is produced at the cathode.

The reactions that take place in the electrolytic cell is:

2 NaCl + 2 H2O = 2 NaOH + Cl2 + H2

The chlorine further reacts with the hydroxide to form sodium hypochlorite
(NaOCl). This reaction can be simplified in the following manner:

Cl2 + 2 NaOH = NaCl + NaClO + H2O

The solution generated has a pH value between 8 and 8.5, and a maximum
equivalent chlorine concentration of less than 8 g/l. It has a very long shelf life
which makes it suitable for storage.

After dosing the solution into the water flow, no pH value correction is
necessary, as is often required in sodium hypochlorite produced by the
membrane method. The sodium hypochlorite solution reacts in a balance
reaction, resulting in hypochlorous acid:

NaClO + H2O = NaOH + HClO

To produce 1kg equivalent of chlorine using on-site Sodium Hypochlorite


generator, 4.5 kg of salt and 4 kilowatt hours of electricity is required. The final
solution consists of approximately 0.8% (8 grams/liter) sodium hypochlorite.
Benefits of Electrochlorination
(ON-SITE SODIUM HYPOCHLORITE GENERATOR)
 Simple: Only water, salt and electricity is required
 Non Toxic: Common salt which is the main substance
is nontoxic and easy to store. Electro chlorinator
provides the power of Chlorine without the danger of
storing or handling hazardous materials.
 Low Cost: only water, common salt and electricity is
needed for electrolysis. The total operating cost of an
Electrochlorinator is less than the conventional
Chlorination methods.
 Easy to dose to get a standard concentration: Sodium
hypochlorite generated on-site does not degrade like
commercial sodium hypochlorite. Therefore, the dosage
need not be modified on a daily basis based on the
strength of the hypo solution.
 Approved disinfection method complying with the drinking water regulations –
an alternative with less safety requirements to chlorine-gas-based systems.
 Long service life, as compared with the membrane cell electrolysis
 On-site generation of sodium hypochlorite allows the operator to produce only
what is needed and when it is needed.
 Safe for the Environment: As compared to 12.5% sodium hypochlorite, the
use of salt and water reduces the carbon emission to 1/3rd. The hypo solution of
less than 1% concentration produced by our system is benign and considered
non hazardous. This translates to reduced safety trainings and improved worker
safety.
Sodium Hypochlorite generated on-site with the help of synthetic brine or seawater is very efficient
in protecting the equipment from the growth of micro organic fouling and control of algae and
crustaceans. Compact Electrochlorinators manufactured by Pristine Water are ideal for disinfection
of water during disasters like earthquakes, Floods or Epidemics. Electrochlorinators are designed for
rural and village 'point -of- use' disinfection of drinking water.
Advantages of On-Site Generation of Sodium Hypochlorite
Although the economic consideration is the major advantage in using On- site
generated Sodium Hypochlorite over the use of other forms of Chlorination, but
the technical advantages are even greater.
The following are some of the problems associated with using commercial grade
liquid sodium hypochlorite. These have high concentration (10-12%) of active
chlorine. These are produced by bubbling gas chlorine in Caustic soda (Sodium
Hydroxide). They are also commonly called as Liquid Chlorine.
Corrosion
The corrosion due to Commercially produced hypochlorite is a concern because
of its effect on equipment. A 10 to 15% hypochlorite solution is very aggressive
due to its high pH and chlorine concentration. Because of its aggressive nature,
the hypochlorite solution will exploit any weakened areas in the hypochlorite
piping system and may cause leaks.
Scaling
The formation of calcium carbonate scale is another concern when using
commercial grade liquid hypochlorite for chlorination. Commercial grade liquid
hypochlorite has a high pH. When the high pH hypochlorite solution is mixed
with the dilution water, it raises the pH of the mixed water to above 9. The
calcium in the water will react and precipitate out as calcium carbonate scale.
Items such as pipes, valves and rotameters may scale up and no longer function
properly. It is recommended that the commercial grade liquid hypochlorite not
be diluted and that the smallest pipe lines, the flow rate will allow, should be
used in the system.
Gas Production
Another concern with commercial grade hypochlorite is gas production.
Hypochlorite loses strength over time and generates oxygen gas as it
decomposes. The rate of decomposition increases with concentration,
temperature, and metal catalysts.
Personal Safety
A small leak in the hypochlorite feed lines would result in the evaporation of the
water and in turn the release of chlorine gas.
Chlorate Formation
The final area of concern is the possibility of chlorate ion formation. Sodium
hypochlorite degrades over time to form the chlorate ion (ClO3-) and oxygen
(O2). The degradation of the hypochlorite solution is dependent on the strength
of the solution, temperature, and the presence of metal catalysts.
Decomposition of Commercial Sodium Hypochlorite can be created by two major
ways:
a). The formation of Chlorates due to high pH, 3NaOCl= 2NaOCl+NaClO3.
b). Chlorine evaporation loss due to temperature increase.
Therefore, for any given strength and temperature, over a period of time, the
higher strength product will eventually be lower in available chlorine strength
than the lower strength product, since its decomposition rate is greater. The
American Water Works Association Research Foundation's (AWWARF) concluded
that the decomposition of concentrated bleach (NaOCl) is the most probable
source of chlorate production. High concentration of Chlorate is not advisable in
drinking water.
Chlorine Comparison Chart
PH Available
Product Form Form
Stability Chlorine
Cl2 gas Low 100% Gas
Sodium hypochlorite(Commercial) 13+ 5-10% Liquid
Calcium hypochlorite granular 11.5 20% Dry
Sodium hypochlorite(On-site) 8.7-9 0.8-1% Liquid
Now which is the ideal disinfectant?
a. Chlorine Gas—this is too dangerous to handle and not safe in residential
areas. Most of the times, they are not available.
b. Bleaching Powder—or Calcium Hypochlorite is effective, but the whole
process of mixing, settling and disposing off of the sludge is very messy and
cumbersome. This makes the whole area dirty. More over, the bleaching powder
absorbs moisture during monsoon or in wet surroundings and emits chlorine
gas, making the bleaching power lose its strength.
c. Liquid Bleach—or Liquid Chlorine -or Sodium Hypochlorite is very effective.
This is in liquid form so very easy to handle. But the commercially available
Liquid Chlorine is not only expensive but looses its strength over a period of
time and becomes water. The danger of spillage is a common problem.
d. Electro Chlorinator—Very effective,economical, safe and easy to prepare
and use. This is the latest technology being adopted in most nations.

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