Process Stack Support

JBW partnered with a food manufacturer to solve a critical challenge with emissions testing on one of their process stacks. Due to vortexing in the exhaust flow, accurate testing could not be performed, and a custom-designed vortex breaker was proposed to correct the issue. The installation presented unique technical difficulties, as the breaker would be subjected to extreme temperatures near 2,000°F and needed to be temporarily suspended 25 feet down inside a 60-foot stack. The client requested a temporary solution that could be installed, tested, and removed within hours, which required careful consideration of materials and support methods.

Initial trials used 317 stainless steel for the breaker and stainless steel wire rope for suspension. While this approach allowed short-term operation, the cables failed twice under prolonged exposure, causing the breaker to fall into the burner. Although the breaker itself sustained minimal damage, the failures highlighted the limitations of cable suspension in high-temperature service. After consultation with the client and contractors, our team redesigned the installation to eliminate this risk. The final solution incorporated 316 stainless steel angle supports welded directly to the breaker, removing all reliance on cables or bolted fasteners.

To further ensure long-term durability, procedures were added to allow the breaker and welded supports to cool for one hour while suspended in place, reducing the risk of thermal warping during cooldown.