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Author Topic: Designing my Generation 2 waste oil boiler.  (Read 204 times)

mlappin

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Designing my Generation 2 waste oil boiler.
« on: October 11, 2017, 06:53:50 PM »

So after building the last waste oil boiler designed around a burner from http://usedoilheatingsystems.com/ I stumbled on a kit to take the an standard fuel oil burner and convert it to waste oil, of course. The one I built works fine, but needs manually lit for starters, then once the water reaches 192 it shuts off automatically but then needs relit again if needed. Primarily I use it for batch burns in the shoulder seasons.

Iím thinking with an automatic setup next time we go overseas for three or four weeks just make sure the oil reservoir is full and let the G200 go out. Father has already proven heís both too set in his ways and/or stubborn to actually follow directions on keeping a gasifier going. Last time we went away for a few days he forgot to fill it in the morning, then that night he just dropped some small crap in the bottom, some more stuff on top and left, got home at 8PM to the red light flashing and 108 degree water on the coldest night that month had to offer.

Anyways, thinking dry base this time lined with firebrick as water cooled metal really quenches the flame, the ceramic blanket directly above my burn pot always has a fine white ash on it as well as the door, everywhere else is a black sooty mess. Keeping it compact as well to regain some floor space, thinking 3-4í long lower burn chamber then to a vertical section with heat exchanger tubes and turbolators, pretty sure I know where I can get some of those. Get a new 250 gallon oblong fuel tank to mount overhead for storage.

Anyways, link to conversion kit.


http://ckburners.com/burnerbuilding.html
« Last Edit: October 11, 2017, 07:01:19 PM by mlappin »
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BoilerHouse

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Re: Designing my Generation 2 waste oil boiler.
« Reply #1 on: October 13, 2017, 07:56:35 AM »

Marty, I will be following this build and good luck with it.  I imagine a source of fuel is not a problem with all the farm equipment that needs to be maintained.
After the vertical HX, will the flue gas pass up to the stack?
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mlappin

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Re: Designing my Generation 2 waste oil boiler.
« Reply #2 on: October 13, 2017, 08:23:37 AM »

Marty, I will be following this build and good luck with it.  I imagine a source of fuel is not a problem with all the farm equipment that needs to be maintained.
After the vertical HX, will the flue gas pass up to the stack?

Thats the plan, going with all vertical tubes and turbolators to avoid having to brush my current setup. It makes a mess no matter what.

Iím gonna talk to a friend, heís one of the few around whoíll actually mess with oil burners yet, I just need a unit that has a good motor and ignition transformer, the pump comes clear of it anyways.
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Homemade skid steer mounted splitter, 30" throat, 5" cylinder
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mlappin

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Re: Designing my Generation 2 waste oil boiler.
« Reply #3 on: October 15, 2017, 07:12:19 AM »

Marty, I will be following this build and good luck with it.  I imagine a source of fuel is not a problem with all the farm equipment that needs to be maintained.
After the vertical HX, will the flue gas pass up to the stack?

Actually since switching to all no-till almost ten years ago we donít generate near the waste oil we used to. If it was a wet year when we still did tillage a few tractors might actually get oil changed twice a year as might work the same piece of ground several times trying to get it to dry out, now most of em barely get a hundred hours a year on em. Also have enough tractors now when making hay one goes on the discbvine, another on the tedder, another on the rake and another on the round baler and they stay there until fall when finally done with hay.

After looking at my current boiler I can just modify the door slightly and slide the gun right in the door after cutting a hole thru both layers then adding a sleeve to it. Iíll gladly post any pictures of what I end up with far as the burner though.


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mlappin

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Re: Designing my Generation 2 waste oil boiler.
« Reply #4 on: October 27, 2017, 10:55:02 PM »

A used oil burner is as hard to find as an honest politician around here. Nobody has one just laying around, so bought a used one off Ebay.

The kit is pretty straight forward, directions pretty concise, wiring was a snap.

If anybody attempts this as well and you use the Beckett AF or AFG just make sure it does NOT have the L1 or V1 head. None of it is reusable. I started out with a fresh blast tube, then had to modify the old electrode holder to work with the heater block, then had to make a centering device, a lathe and bridgeport came in handy there. I need to sleeve my door yet and waiting on a brass float kit to show up from Amazon. Iíve played around a little bit with it, even with the preheater block, the temp of the incoming oil is critical. Anything below 50 and forget it. I think Iím going to set up a heater on the float reservoir then use a normally open and a normally closed solenoid valve. Reprogram the Honeywell controller to run the fan after the ignition cycle for like a purge, hook the air solenoid to the motor lead, then the fuel solenoid connection on the controller to the NO/NC solenoids so when its done burning the one close and cuts the oil off at the tank and the other opens to vent the line so I can purge it so it doesnít have the possibility of having cold oil in it. Kinda like how DEF systems purge all the lines when the engine is shut off.
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Homemade skid steer mounted splitter, 30" throat, 5" cylinder
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mlappin

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Re: Designing my Generation 2 waste oil boiler.
« Reply #5 on: October 30, 2017, 09:11:45 PM »

Success, sleeved the door tonight, a plasma cutter even blasts thru Kwool.

Still waiting on the blasted float.
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mlappin

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Re: Designing my Generation 2 waste oil boiler.
« Reply #6 on: November 02, 2017, 02:48:43 PM »

About 90% success on cold starts.

Iím sure the other 10% will be taken care of by having an actual float so the oil level is always the same as well as preheating it to 80-100 degrees.
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mlappin

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Re: Designing my Generation 2 waste oil boiler.
« Reply #7 on: November 05, 2017, 03:59:14 PM »

Still waiting on the brass float, ordered from Amazon, fulfilled by Gatzies. Never heard of em, they suck, had my other stuff for a week before they even got around to shipping the float. Then to top it all off they shipped DHL, had experience with DHL before, they lost a part that took days and dozens of phone calls to find, found one of the last ones in North America, was shipped from Canada and they lost it. Had to buy literally the last one the salvage yard had left that was to be found anywhere in North America, six months later the original showed up via UPS, guess DHL was too ashamed to show up in our driveway since their mistake cost us weeks during harvest.

Only experience worse Iíve had with shipping was from the good ole tax subsidized USPS, bought an owners manual from California and they shipped it USPS, took five weeks to show up and it seen more of the USA than I have by time it finally got here.
« Last Edit: November 05, 2017, 04:01:48 PM by mlappin »
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Homemade skid steer mounted splitter, 30" throat, 5" cylinder
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mlappin

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Re: Designing my Generation 2 waste oil boiler.
« Reply #8 on: November 08, 2017, 06:53:45 PM »

Got it figured out, not sure why, but unless my oil is at least 80 degrees forget it. It does have the heater block that the siphon nozzle attaches to, however it is aluminum and the thermocouple measure block temperature, not actual oil temperature. Maybe cause my oil is mostly engine oil out of diesels with some hydraulic oil and gear oil mixed in. Maybe oil out of standard cars and trucks has more gas in it from ring blowby although I think it would evaporate away. Actually I think the big problem is my one uncle and his friends keep giving me oil they drain out of their Harleys, least bit cold and those donít like to start either.

Have a heater built into my oil reservoir now that the float finally showed up, a consistent oil level, warm oil, and purging the oil line so itís empty instead of full of cold oil has resulted in a 100% fire rate, most of the time within seconds once the oil reaches the nozzle, you can tell by listening to it when the oil gets there. Still waiting on a normally open 110v solenoid to show up, will wire that up so the air solenoid is on with the blower motor and have the two solenoids for the oil wired to the optional fuel terminal on the controller. Will program so the blower keeps running when it shuts off but the juice will be shut off to the oil solenoids. The normally closed will shut and cut the oil  supply off while the normal open will open with the absence of power and will allow the line to vent since it will still have air to the nozzle.

Need to get a better regulator on it, it may be a name brand, but it sucks. I expect a little creep of course when the solenoid shuts off, but even when running it may need adjusting a few times an hour. I even have another regulator ahead of it set to 25 lbs.
« Last Edit: November 08, 2017, 06:56:20 PM by mlappin »
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Stihl 023
Stihl 362
Stihl 460
Sachs Dolmar 112 and 120
Homemade skid steer mounted splitter, 30" throat, 5" cylinder
Wood-Eze model 8100 firewood processor

HeatmasterSS dealer for Northern Indiana