Rusting Venting

Why does the venting “rust” out? I have always been told it is because of the condensation created when
the flue temperature falls below the dew point.

Wikipedia definition of Dew Point: http://en.wikipedia.org/wiki/Dew_point

The dew point is the temperature to which a given parcel of air must be cooled, at constant
barometric pressure, for water vapor to condense into water. The condensed water is called
dew. The dew point is a saturation point.

With that said, under certain conditions; temperature, humidity and barometric pressure; condensation
will form on an object from the moisture in the air. So we must keep the temperature of the flue gasses
high enough to stay above the dew point. But it is not quite that simple because we add one more
element into the mix. Not quite understanding exactly what was happening, I did a little research on the
web.

The following information was found in an article for a patent application titled: BIOFUEL APPLIANCE
VENTING SYSTEM. To see the entire article, go to:
http://www.faqs.org/patents/app/20090139510#ixzz0TTVt7xAR. I’ve pulled some of the more important
information for us out of the article.

“Some biomass fuels emit an exhaust when burned that contains corrosive chemicals.” This is corn when
burning.

“Elevated levels of potassium chloride and potassium sulfate salts in the air emissions from corn
combustion along with elevated levels of acid gases (sulfur dioxide and nitrous oxides) producing acidic
emissions were found.”

“Analyses of bulk corn fuel confirm high levels of nitrogen, sulfur, chlorine, and potassium as compared to
typical wood pellets.” This is why the venting will last longer when burning wood pellets.

“Tests of corroded pipe confirmed the corroded material on the pipe surfaces as being enriched in sulfur,
chlorine and potassium.” The test showed the gunk on the pipes was of a corrosive nature.

“Also contributing to corrosive nature of corn combustion emissions are the elevated phosphorous levels
in corn producing phosphoric acid and phosphate salts upon combustion and the elevated levels of
ammonium salts in the air emissions, most likely originating from the incomplete combustion of amino
acids”. This is basically is what I was taught, especially when combined with water vapor (condensation).
With the corrosive chemicals mixed in the condensation and just laying on the walls of the vent, it
becomes easier to understand part of the “why”.

“Conditions that increase the potential for condensation include corn with unusually high moisture
content, a long chimney allowing for emissions to cool, and a cold climate with a high relative humidity, or
a combination of them.” Although the Bixby stoves can burn corn of higher moisture content, we can see
where this could contribute to the venting “rusting” out sooner than with a lower moisture content corn.

“It is speculated that the higher moisture content of corn as compared to typical wood pellets may also
contribute to the corrosion problem due to the increased potential of condensed water (with a low pH and
corrosive salts in solution) being in prolonged and direct contact with pipe surfaces.”

As to which material will stand up to the corrosive environment, the article states:

“Grade 316 is a standard molybdenum-bearing grade stainless steel. The molybdenum gives 316 better
overall corrosion resistant properties than Grade 304,particularly higher resistance to pitting and crevice
corrosion in chloride environments.”
“Although the 444 and AL29-4C.RTM. samples performed equally well, it was determined that the 444
material would make a superior venting system for a biomass fuel having the exhaust characteristics
including the compounds in relative percentage as that of the test solutions.”

“……AL29-4C note that the maximum use temperature should be restricted to 600 F.”
“……444 may experience embrittlement if subjected to long-term exposures of 885.degree F.”

Hopefully we now have a somewhat understanding of how and why the venting can “rust” out. But to be
technically correct, the venting corrodes due to the corrosive effects of the chemicals in the flue gasses.
To help, we can do several things to help make our venting last as long as possible.

1) Keep the stove in good tune.

2) Keep the venting system as short as possible.
3) Use corn with moisture content less than 15%.
4) Run the strove at higher levels rather than lower levels.
a. If you do need to run on lower levels, once in a while run the stove hot to burn the
condensation in the venting out. The longer condensate with corrosive chemicals sits, the
greater the damage it can do.
5) When using a direct vent system, make sure it is not drawing exhaust fumes back into the fresh
air supply pipe. Any exhaust that returns in the intake pipe will condensate quickly as the
temperature drop will be great. This will cause the condensate to attach to the walls of the venting
and more likely settle at the bottom of the pipe, thus corroding the pipe.

After reviewing all of this information, I can see why those that use a single vent for the exhaust have their
venting last much longer than stoves using a direct vent system. It appears to me that the single vent duel
wall vent has better insulation to allow the flue temperatures to remain higher than a single wall pipe
exposed to the cold air.

Likewise , I can see how the direct vent systems of those that run their stoves on the higher levels also
have venting that last a long time. I could also see how a different termination cap to move the exhaust
farther away from the intake air would be of great benefit. This would probably give enough separation of
the exhaust and intake to keep all exhaust from entering into and with the fresh air. Without any chance of
exhaust entering the intake, even on windy days, I believe the stove would stay in tune more consistently.
Remember if any exhaust is drawn in with the intake air the stove’s burn will richen up some and the
exhaust temperature will drop some due to the lower flame temperature.

The ideas expressed here are mine and mine only and are not connected in any way or form to Bixby
Energy Systems.

October 2009
Quark