DIY pyrolysis boiler

Pyrolysis - this is the name of the process in which the slow combustion of fuel occurs. It is accompanied by the formation of a gaseous medium.

This process underlies the operation of boiler equipment, which in its efficiency can be comparable with gas.

Buying a pyrolysis boiler is optional: you can do it yourself. Below we will explain in more detail how to do this.

The originality and feature of the pyrolysis boilers

Advantages of boilers

Pyrolysis boilers have the following advantages.

1. When burning fuel no soot, soot and other combustion waste is released. Pyrolysis furnaces belong to one of the most environmentally friendly species furnace equipment.
2. Any dry fuel can be used as fuel., for example, waste from sewing industry. Good quality fuel can ensure continuous operation of the boiler on the basis of the pyrolysis furnace for 12 hours. I.e firewood can be loaded twice a day.
3. Use of such a furnace allows to reduce the cost of heating utilities by 50-60% per year. Using pyrolysis technology allows you to automate the furnace control processes, and this accordingly increases the safety of the device as a whole.

Disadvantages

Meanwhile, in boilers of this type there are certain disadvantages.

To buy a finished boiler and start it up, you need to invest a certain amount, but it is worth noting that the cost-effectiveness of this device will be visible almost immediately.

Operational Features

One of the difficulties of operating such a device is related to the fact that, the fuel to be used must have a moisture content of about 20%. Otherwise, combustion will stop. I.e fuel must go through the drying process. This operation can complicate the design of the device and reduce its efficiency.

In some cases, an electric pump is used to pump air, then the operation of the equipment becomes dependent on electricity.

This information must be borne in mind when proceeding with the independent manufacture of the boiler.

Materials and tools for manufacturing

Before you start creating this type of furnace, you need to collect a fairly wide range of tools and materials.

The following is a sample list.

1. Electric drill.
2. Welding machine. Experience suggests that it is advisable to use a DC model.
3. Electrodes for welding.
4. Angle grinder.
5. Cutting and grinding wheels with a diameter of 125 mm. If the sheet for the manufacture of the furnace will be cut independently, then a cutting wheel with a diameter of 230 mm will be required.

Material for the manufacture of the furnace, as a rule, is given in the specification included in the set of working documentation. But anyway a sheet with a thickness of 4 mm, profiled pipes with a wall thickness of 2 mm, a certain amount of strip metal with different widths and thicknesses will be in demand. In addition to the metal from which the furnace will eventually be built, it will be required fan and temperature sensor.

Important! The pyrolysis boiler differs from other equipment in that it burns not only fuel, but also the gas released during its combustion.

Scheme and drawings of the pyrolysis boiler

For a better understanding of the principle of operation of this equipment, it makes sense to understand how such a boiler works, to disassemble its circuit diagram.

The pyrolysis furnace consists of the following parts.

1. Gasification chambers.
2. Afterburners
3. Air supply systems (primary, secondary).
4. Water shirt.
5. Grate.

In addition, the pyrolysis boiler design includes water supply pipes, combustion chamber, control equipment, fan and some other units.

A pyrolysis boiler is a rather complicated technical device. With its independent production, it is necessary to strictly comply with all the requirements of the working documentation.

We offer a drawing of the boiler, which is useful in the manufacture.

The internal structure of the boiler will help to understand the following diagram.

Usually, for heating a country house, a 40 kW boiler is enough. If this indicator needs to be adjusted, then some parameters of the furnace can be changed.

In order to make a boiler, it is necessary to prepare its main structural elements.

Step-by-step instruction for the manufacture of a pyrolysis boiler

Body

For the manufacture of a boiler body of long burning, sheet steel is used.

• Using an angle grinder, parts are prepared in accordance with the drawings.
• Inside the walls, places are prepared under the doors of the ash pan and for loading fuel. The main thing when performing work is compliance with all requirements of working documentation.
• A welding machine is used to connect sheet parts.
• After receiving the finished parts the resulting seams must be cleaned from scale. To do this, use a small angle grinder with a mounted grinding wheel.
• Thereafter weld the nozzles in such a way that there are no gaps between the seams.
• Protective heat exchangers must be installed on the back of the boilerto.
• After testing for leaks you can install the back wallmade of heat resistant steel.
• In the next stage of manufacturing the furnace is necessary install the partition, which will separate the gasification and gas combustion chambers, making a grate made of cast iron.
• On top of the gasification chamber, an air duct is installed together with a damper. An air duct is installed at the bottom of the chamber. After this, the firebox is immediately finished with fireclay (heat-resistant) brick.
• Finishing is performed from below and on the sides.

Doors

For boiler doors, you will have to buy a sheet of heat-resistant steel.

To increase rigidity, they are reinforced with a steel corner, welding it to the inside.

Assembly

Such a boiler can be installed in non-residential premises.

Assembly is carried out in the following order.

• Attach the chimney.
• After that, pipes to which the working medium of the heating circuit will be transported are reinforced to the boiler.
• Installation is considered complete after installing the smoke pump.

Tips for making a pyrolysis boiler

• In the manufacture of this equipment is necessary strictly comply with the requirements of the working drawings, and the work itself must be carried out using a quality tool.
• Since the grinder will be used during operation, when processing welds, personal protective equipment must be used: glasses, gloves, respirator.
• Everything work must be carried out in compliance with the requirements of safety and labor protection.
• Upon completion of work on the surface of the finished furnace it makes sense to apply a protective coating that protects the furnace from corrosion.
• When manufacturing or purchasing a finished chimney, you must pay attention to ensure that it is made with a minimum of knees. This will facilitate the passage of combustion products.
• Pyrolysis boiler must be installed on a solid base. Under him need to establish a simple foundationwhich does not need to be buried. Enough to fill a flat area of ​​concrete.