V.

DRAFT SYSTEM

LEARNING OUTCOME

1. Explain the importance of draft systems.

2. Define the different terminologies in draft system.
3. Explain and derive the draft system flow resistance equation.
4. Solve example problems.

The combustion process in the furnace can only take place when:
a) there is a steady flow of supply air and
b) the combustion gases (products of combustion) are constantly removed.

TERMINOLOGIES

1. DRAFT SYSTEM – A major part in a steam generator which induces steady flow of atmospheric air
and constant removal of gases.

2. DRAFT – The difference between absolute gas pressure at any point in a gas flow passage
(Furnace, chimney, air heater, etc. ) and the ambient atmospheric pressure.

D = Pgas – Patm
D (+) if Patm < Pgas
D (–) if Patm > Pgas

3. NATURAL DRAFT – Used only in small boilers where chimney is used.

4. MECHANICAL DRAFT – Used in large capacity steam generators where the flow of air and gas
augmented by forced draft fan or induced draft fan or both.

5. DRAFT LOSS - The pressure loss caused by friction between two points in the gas-flow path.

6. CHIMNEY/STACK – Vertical passage used to discharge gases and fly ash high enough above the
ground to dilute them with air and minimize air pollution.
– maximum economical height = 200 feet 0r 60 meters.

The net movement of combustion gases in a steam generator is vertically upwards as they flow from
furnace to convection passes to air heater and to stack. The hot gas weighs less than an equal
column of cold outside air. This causes a pressure difference that moves a flow of air and gas steadily
through the fire side of the steam generator. This pressure difference is called the static stack draft
or net stack effect.

7. STATIC STACK DRAFT/NET STACK EFFECT – The maximum pressure difference that creates steady
flow of air and gas.

12
Ds = hs( ρa – ρg), in. H2O
62.4

hs
Ds = ( ρa – ρg), cm H2O
10

1
 where:
Ds = Stack Draft or Net Stack Effect

Ds = Dchimney ± Dvertical passages

( + ) – Direction of flow is upwards
( – ) – Direction of flow is downward

hs = Stack or chimney height ( ft. , mtrs. )

ρa = Air Density ( lbs/ft3 , kg/m3 )

ρg = Gas Density ( lbs/ft3 , kg/m3 )

8. DRAFT SYSTEM FLOW RESISTANCE EQUATION – The balanced flow pressure pattern in a draft
system.

DF + D S = D A + DG + DV in. of H2O or cm. of H2O

Where: DF = Total fan effect pressure

DS = Net stack effect

DA = Draft loss on air side

= Dair heater + Dwind box + Dfuel bed + Dair passages

DG = Draft loss on the gas side

= Dair heater + Dboiler + Dsuperheater + Deconomizer + …
… + Ddust collector + Dbreeching + Dgas passages

DV = Draft loss due to gas exit velocity

(Vexit)2
DV =
2g

9. CHIMNEY AND DUCT LOSSES DUE TO FRICTION:

ρ f V2 L
Df =
10 2gRh

Where: Df = Head loss due to friction, cm of fluid

L = Linear length of duct including bends, m
V = Mean flow velocity, m/sec
ρ = Density of fluid, kg/m3
Duct cross-section area, m2
Rh = Hydraulic radius =
Wetted perimeter, m
g = Gravitational acceleration = 9.8066 m/sec2
f = Friction factor as follows:
Air: against steel, 0.005
against masonry or concrete, 0.007
Gas: against steel, masonry or concrete, 0.014
2
 Forced Draft Fan

Air Duct

S
t
a
c
k E
c
Induced Draft Fan
o
n
Breeching Air o Super
Heater m heater
i
z Fuel Bed Traveling
e Grate
r Stoker

Dust Collector Air Duct

Wind Box

Refuse Pit

TYPICAL DRAFT SYSTEM OF A LARGE STEAM GENERATOR

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Examples

1. Problem 9.1, page 200, Vopat: Flue gas flows through three vertical passages A, B and C in series
in that order. Data are as follows:

Passages Element Height, m Flow Temperature, OC

A Economizer 18 Up 843
B Air Heater 38 Down 593
C Chimney 46 Up 138

Assume a gas density of 0.6705 kg/m3 at 260OC and an air density of 1.232 kg/m3 at 15.6OC.
Calculate the draft at the entrance to passage A due to stack effect.

2. Problem 9.5, page 202, Vopat: Compute the motor capacity needed for the forced draft fan
under the following conditions:

Coal rate, 10 Tons/hr

Coal analysis, %:

C = 78.0 H = 3.0 O = 3.0

S = 1.0 A = 8.0 W = 7.0

Excess air, 30%

Plenum chamber pressure, 17.78 cm H2O
Mechanical efficiency of fan, 60%.

3. Problem 9-6, page 202, Vopat: The draft system of a boiler consists of a stack and forced draft
fan. A 200-sq ft (18.60-sq mtr) traveling-grate stoker is employed, burning anthracite coal.
Estimate the stack height and fan motor capacity for the following data:

Flue-gas temperature, 500OF (260OC)

Inlet air, 14.7 Psia and 75OF (101.325 kPaa and 24OC)
Coal heating value, 12,800 Btu/lb (29,709 kJ/kg)
Excess air, 25% with buckwheat #2 coal
Combustion rate of fuel bed, 35 lb/ft2-hr (171 kg/m2-hr)
Stack friction draft plus velocity pressure, 0.042 in. H2O (1.067 mm H2O)
Boiler and breeching loss, 0.65 in. H2O (16.50 mm H2O)
Fan mechanical efficiency, 70%

4. Problem 38, 39, page 508, Morse: A boiler plant expected to burn 749.3 kg of 31,750 J/g coal
per
hour with 44% excess air. The
gas loop is designated in the
Radial Brick 315.6OC
122 cm Ø x 54.86 m

figure. The boiler draft loss is

Atm 32.2OC
1.14 cm H2O at this rate of
combustion, and the fuel bed
resistance is 8.26 cm H2O. Find Boiler
the draft available at the base
3 – 90O bends
of the chimney. Find the FD Fan O
2 – 90 bends 91.4 cm x 91.4 cm x 45.72 m
pressure drop required of the
boiler outlet damper in order to 30.5 cm x 50.8 cm x 7.62 m

4
 have a 0.25 cm H2O furnace pressure. Find the fan drive horsepower to be recommended for
the installation assuming that the total efficiency of the fan is 70% at rated capacity.

Solutions

1. Problem 9.1, page 200, Vopat: Flue gas flows through three vertical passages A, B and C in series
in that order. Data are as follows:

Passages Element Height, m Flow Temperature, OC

A Economizer 18 Up 843
B Air Heater 38 Down 593
C Chimney 46 Up 138

Assume a gas density of 0.6705 kg/m3 at 260OC and an air density of 1.232 kg/m3 at 15.6OC.
Calculate the draft at the entrance to passage A due to stack effect.

Passage A

Pa
a =
RaTa

Pa = a Ra Ta

Pa = 1.232 x 0.287 x (15.6 + 273)

Pa = 102.044 kPa

Pg = gRg Tg

Pg = 0.6705 x 0.287 x (260 + 273)

Pg = 102.567 kPa

DsA =
hsA
(a − gA )
10

Pg
gA =
Rg TgA

102.567
gA =
0.287(843 + 273)

gA = 0.320 kg/m3

DsgA =
hSA
10
(a − gA )

5
 18
DsgA = (1.232 − 0.320)
10

DsgA = 1.642 cm H2O

Passage B

Pg
gB =
Rg TgB

102.567
gB =
0.287(593 + 273)

gB = 0.413 cm H2O

38
DsgB = (1.232 − 0.413)
10

DsgB = 3.112 cm H2O

Passage C

Pg
gC =
Rg TgC

102.567
gC =
0.287(138 + 273)

gC = 0.869 cm H2O

46
DsgC = (1.232 − 0.869)
10

DsgC = 1.670 cm H2O

DS = DSgA – DSgB + DSgC

DS = 1.642 – 3.112 + 1.670

DS = 0.20 cm H2O

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2. Problem 9.5, page 202, Vopat: Compute the motor capacity needed for the forced draft fan
under the following conditions:
Coal rate, 10 Tons/hr
Coal analysis, %:
C = 78.0 H = 3.0 O = 3.0
S = 1.0 A = 8.0 W = 7.0
Excess air, 30%
Plenum chamber pressure, 17.78 cm H2O
Mechanical efficiency of fan, 60%.

Motor HP =
(Q ,m 3
)
/ min (DA , cm.H2O)
(450)(m )

Waa , kg / min
Q=
a , kg / m3

Waa = wf x waa

waa = wta(1 + e)

 O 
w ta = 11.53C + 34.36 H2 + 2  + 4.32S
 8 

 0.03 
w ta = 11.53(0.78 ) + 34.36 0.03 +  + 4.32(0.01)
 8 

wta = 9.94 kga/kgf

waa = 9.94 (1 + 0.30) = 12.922 kga/kgf

Waa = (12.922 kga/kgf) x (10,000 kg/hr) x 1hr/60 min

Waa = 2,153.67 kg/min

Pa 101.325
a = = = 1.23kg / m3
RaTa (0.287)(15.6 + 273)

2,153.67
Q= = 1750.95 m3/min
1.23

Motor HP =
(1750.95m 3
)
/ min (17.78cm.H2O)
(450 )(0.6 )

Motor HP = 115.24 HP

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3. Problem 9-6, page 202, Vopat: The draft system of a boiler consists of a stack and forced draft
fan. A 200-sq ft (18.60-sq mtr) traveling-grate stoker is employed, burning anthracite coal.
Estimate the stack height and fan motor capacity for the following data:

Flue-gas temperature, 500OF (260OC)

Inlet air, 14.7 Psia and 75OF (101.325 kPaa and 24OC)
Coal heating value, 12,800 Btu/lb (29,709 kJ/kg)
Excess air, 25% with buckwheat #2 coal
Combustion rate of fuel bed, 35 lb/ft2-hr (171 kg/m2-hr)
Stack friction draft plus velocity pressure, 0.042 in. H2O (1.067 mm H2O)
Boiler and breeching loss, 0.65 in. H2O (16.50 mm H2O)
Fan mechanical efficiency, 70%

DBo + DBr = 16.5 mm

H2O
DCh + DV = 1.067 mm
H2O H2O
FD Fan

DS =
hS
(a −  g )
10

Pa 101.325
a = = = 1.19 kg/m3
R a Ta (0.287)(24 + 273)

Pg 101.325
g = = = 0.662 kg/m3
Rg Tg (0.287)(260 + 273)

DF + D S = DA + DG + DV

DS = D G + DV

DG = DBo + DBr + DCh

DS = DBo + DBr + DCh + DV = 1.65 + 0.1067

DS = 1.7567 cm H2O

10xD S 10x1.7567
hS = =
a −  g 1.19 − 0.662

hs = 33.27 m

Fan HP =
(Q A )x(DA )
(450 )x(m )

8
 7.65(HHV ) 7.65(29,709kJ / kg )(1Btu / 1.055kJ)(1kg / 2.2lb)
w ta = = = 9.792 kga/kgf
10,000 10,000

waa = (wta)(1 + e) = 9.792(1.25) = 12.24 kga/kgf

wf = (Combustion rate)(Fuel bed area)

wf = (171 kg/m2-hr)(18.6 m2) = 3,180.6 kgf/hr = 53.01 kgf/min

Waa = (waa)(wf) = (12.24 kga/kgf)( 53.01 kgf/min)

Waa = 648.842 kga/min

Waa 648.842
QA = =
a 1.19

QA = 545.246 m3/min

DA = DFB = 43 mm H2O = 4.3 cm H2O ------ Fig. 12-34 page 476, Morse

Fan HP =
(545.25)x(4.3)
(450)x(0.70)

Fan HP = 7.443 HP

4. Problem 38, 39, page 508, Morse: A boiler plant expected to burn 749.3 kg of 31,750 J/g coal
per
hour with 44% excess air. The
gas loop is designated in the

Radial Brick 315.6OC

122 cm Ø x 54.86 m
figure. The boiler draft loss is
Atm 32.2OC
1.14 cm H2O at this rate of
combustion, and the fuel bed
resistance is 8.26 cm H2O. Find Boiler
the draft available at the base of
3 – 90O bends
the chimney. Find the pressure FD Fan 91.4 cm x 91.4 cm x 45.72 m
2 – 90O bends
drop required of the boiler
outlet damper in order to have 30.5 cm x 50.8 cm x 7.62 m

a 0.25 cm H2O furnace

pressure. Find the fan
drive horsepower to be recommended for the installation assuming that the total efficiency of
the fan is 70% at rated capacity.

From the Draft System Flow Resistance Equation,

DF + D S = DA + D G + DV

DS = D G + DV

DG = DBoiler + DGasPassage + DBreeching + DChimney

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DS = DBoiler + DGasPassage + DBreeching + DChimney + DV

DBreeching = – DBoiler – DGasPassage – DV

DBoiler = 1.14 cm H2O

 fg Vg2L 
DGasPass = 
 2gRh 
 

fg = 0.014 for gas against concrete

Qg
Vg =
Ag

Wg
Qg =
g

Wg = Waa + Wf

Wf = 749.3 kg/hr

Waa = wf x waa

waa = wta x (1 = e)

7.65(HHV )
waa = x(1 + e)
10,000

7.65(31,750, kj / kg )(1Btu / 1.055kJ)(1kg / 2.2lbs)

waa = x(1 + 0.44 )
10,000

waa = 15.07 kga/kgf

Waa = (15.07 kga/kgf) x (749.3 kgf/hr) = 11,291.95 kga/hr

Wg = (11,291.95 + 749.3) kgg/hr x 1hr/60 min = 200.7 kgg/min

101.325
g = = 0.6 kg/m3
(0.287)(315.6 + 273)

200.7
Qg = = 344.48 m3/min
0.6

344.48, m3 / min
Vg = = 412.36m / min = 6.873m / sec
(0.914 )x(0.914 ), m2

L = 45.72 + (3 x ½) = 47.22 m

10
Rh =
(0.914 )x(0.914 ) = 0.228 m
4x0.914

0.60  0.014x6.8732 x47.22 

DGasPass =  
10  2x9.8066x0.228 

DGassPassage = 0.419 cm H2O

2
VCh
DV =
2g

Q g 344.48x1 / 60
VCh = =
A Ch x1.222 / 4

VCh = 4.911 m/sec

4.9112
DV = = 1.23 cm H2O
2x9.8066

DBreeching = –1.14 – 0.419 – 1.23

DBreeching = – 2.789 cm H2O ------ Pa > Gas pressure at the chimney base

ΔPBo = DBo – PFurnace = 1.14 – 0.25

ΔPBo = 0.89 cm H2O

Fan HP =
(Q A )x(D A )
450x mF

Waa
QA =
a

101.325
a = = 1.157 kg/m3
(0.287)(32.2 + 293)

QA =
(11,291.95,kg / hr )x(1hr / 60 min) = 162.654
m3/min
1.157,kg / m3

DA = DAirPassage + DFuelBed

 a  fVa2L A 
D AirPass =  
10  2gRh 

f = 0.005 --- Air against steel

Va =
QA
=
( )
162.654 ,m3 / min (1min/ 60 sec )
= 17.6 m/sec
AA (0.305m)(0.508m)

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 LA = 7.62 + (2x1/2) = 8.62 m

Rh =
(0.305m)(0.508m) = 0.095 m
(2x0.305m) + (2x0.508m)

DAirPass = 
( )
1.157  (0.005) 17.62 (8.62) 
 = 0.829 cm H2O
10  2(9.8066 )(0.095) 

DA = 0.829 + 8.26 = 9.089 cm H2O

Fan HP =
(162.654,m 3
)
/ min (9.089 , cmH2O)
(450 )(0.70 )

Fan HP = 4.693 HP

Exercises:

1. The boiler of a tobacco processing plant burns 4,555 kg per hour of hard black coal with 27%
excess air and a heating value of 24,887 j/g. The net stack effect is 25.615 cm of water. Ambient
temperature is 32OC and average gas temperature is 280OC. Atmosphere is 1 Bar. Forced draft
fan mechanical efficiency is 60%. Determine the minimum stack height and the forced draft fan
motor capacity of the boiler installation shown below if the following draft losses in cm of water
are considered:
Boiler = 0.508
Superheater = 6.35
Economizer = 4.32
Precipitator = 1.9

Stack Diameter = 200 cm

Breeching = 1.65

Superheater
Economizer

15 m
Boiler All passages in
90 cm x 90 cm

gas side are made

of masonry bricks
5m

Gage 20 GI Sheet w/ 3-90O Bends Precipitator

25 m
FDF 90 cm x 90 cm Breeching
75 cm x 70 cm x 30 m

2. Find the draft loss in rectangular breeching 2.59m x 3.67m x 30.48m long when 196 m 3/sec flue
gas of 0.769 kg/m3 density are flowing.

3. What is the friction loss in cm of water in a 2.44m diameter chimney 61m high up which gas is
flowing at 9.14 m/sec? Gas density is 0.6776 kg/m3.

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