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RogerRabbit
Bans for Pleasure



Registered: 03/26/03
Posts: 42,214
Loc: Seattle
Last seen: 11 months, 3 days
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My Homebuilt Wood-Fired Steam Generator 2
#15259802 - 10/22/11 12:04 AM (12 years, 3 months ago) |
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Here's the reason for my absence over the last month or so. Been building this new steam boiler. Last winter, I spent way too much money on propane to heat the greenhouse and sterilize 100+ lbs of sawdust daily. I just found out the cost of propane up here increased by another dollar a gallon for this winter, so something had to be done. Besides, I wanted to take Mountain Mushroom Farm away from using fossil fuels anyway.
This boiler uses an airtight combustion chamber. The only means for air to enter is via the automated air intake mechanism on the bottom. The door is opened by a solenoid, which is controlled by the pressure switch. If pressure drops in the boiler, it opens the air intake to heat up the firebox, raising the pressure in the boiler. If the pressure rises 1/4 psi above the setpoint, an electrically controlled dump valve opens to vent excess steam from the boiler. This provides for near perfectly stable pressure, regardless of whether the firebox is fully loaded or not.
Combustion air enters the front of the unit, and then drops down and passes below the firebox, before entering into the combustion chamber from the rear of the unit. Passing the air through a plenum under the firebox super-heats the air before being introduced, providing for a much hotter and cleaner burning flame. Secondary air intakes are located directly above the fire and provide heated air to the tips of the flames to complete combustion and reduce smoke.
This thing has enough power to supply steam to ten operations the size of mine. I have it throttled down to less than 5% power and still need to dump steam from time to time to prevent overpressure.
These pictures are pretty much in the order the construction proceeded. Most are self-explanatory.
The Slab:

The Air Intake System:

Firebox Door:

The Firebox:

Finished product:

I have an unlimited bio-fuels source only ten miles away, where a forest fire in 2001 killed the trees, but left them standing and perfect for firewood:
I'll put a detailed writeup on this on my website soon. Just wanted to share a few pictures in the meantime. In the next few days, I'll be building an awning over the boiler to keep it out of rain and snow, and putting a coat or two of high temp paint on the door and air intake mechanism. The automatic water feed system is the same as shown in the fully automated 55 gallon boiler thread, so I didn't repeat the info here. RR
-------------------- Download Let's Grow Mushrooms semper in excretia sumus solim profundum variat "I've never had a failed experiment. I've only discovered 10,000 methods which do not work." Thomas Edison
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EvilMushroom666
Heretic




Registered: 11/18/09
Posts: 10,289
Loc: Canada
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Re: My Homebuilt Wood-Fired Steam Generator [Re: RogerRabbit]
#15260724 - 10/22/11 07:15 AM (12 years, 3 months ago) |
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Thanks for sharing!
I cannot wait to read a more detailed write up when you have it posted over at your site. In the future I hope to build my own steam boiler and autoclave and looking over your builds allows me to anticipate my design and soak in information before I myself take the plunge.
How much of an increase in fire wood will you use over the winter do you figure now that your house and boiler will be powered by wood?
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RogerRabbit
Bans for Pleasure



Registered: 03/26/03
Posts: 42,214
Loc: Seattle
Last seen: 11 months, 3 days
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Re: My Homebuilt Wood-Fired Steam Generator [Re: EvilMushroom666]
#15260829 - 10/22/11 08:08 AM (12 years, 3 months ago) |
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We've been averaging about 4 cords per year for our house. I suspect this boiler will burn 6 cords. I'm looking for a cast iron radiator to install in our house, so I can use this boiler to heat it too. That will definitely save on wood cutting. RR
-------------------- Download Let's Grow Mushrooms semper in excretia sumus solim profundum variat "I've never had a failed experiment. I've only discovered 10,000 methods which do not work." Thomas Edison
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ife
Stranger Danger


Registered: 04/10/11
Posts: 116
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Re: My Homebuilt Wood-Fired Steam Generator [Re: RogerRabbit]
#15260855 - 10/22/11 08:18 AM (12 years, 3 months ago) |
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inspirational
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NSF
Eager to learn


Registered: 01/27/11
Posts: 548
Last seen: 7 years, 8 months
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Re: My Homebuilt Wood-Fired Steam Generator [Re: RogerRabbit]
#15260858 - 10/22/11 08:19 AM (12 years, 3 months ago) |
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Great polished work as always RR. Hydronic heating is fantastic.
Pardon my ignorance but i'm not familiar with a cord as a measure. So what is it?
Also, you fire automatically draws air but how does it draw more fuel? And how often do you think you'll need to clear ash from it? That last question is very minor.
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EvilMushroom666
Heretic




Registered: 11/18/09
Posts: 10,289
Loc: Canada
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Re: My Homebuilt Wood-Fired Steam Generator [Re: RogerRabbit]
#15260867 - 10/22/11 08:23 AM (12 years, 3 months ago) |
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I like how you are constantly trying to close the circle so to speak as far as a sustainable system, and using the products of one process to fulfill another need. It is very inspiring 
NSF:
http://en.wikipedia.org/wiki/Cord_%28unit%29
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mycoelf
Agent Of Chaos



Registered: 06/26/09
Posts: 555
Loc: hyperspace
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Re: My Homebuilt Wood-Fired Steam Generator [Re: RogerRabbit]
#15260883 - 10/22/11 08:28 AM (12 years, 3 months ago) |
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Nice work RR, I have often wondered about propane consumption in your operation and how that affects your overhead, this was a REALLY good move on your part, fossil fuels will only go up in cost and processing as much media as you do something had to give. Are you continuing to vent steam into the underground trailer as a source of heat for your grow? and are U using the low pressure setup on the barrel with the new boiler?
I am a retired craftsman and I have to say I am also impressed with your fabrication skills, You are a man of many trades, and that is what it takes these days to surthrive.
Looking forward to reading updates
-------------------- Mycoelf Sterility is a process that can be likened unto infinity, which is a long walk, the closer to the end you start before beginning, the more achievable the goal of infinity becomes. Remember, cleanliness in next to goddessness
      
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mycoelf
Agent Of Chaos



Registered: 06/26/09
Posts: 555
Loc: hyperspace
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Re: My Homebuilt Wood-Fired Steam Generator [Re: NSF]
#15260892 - 10/22/11 08:32 AM (12 years, 3 months ago) |
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Quote:
NSF said: Pardon my ignorance but i'm not familiar with a cord as a measure. So what is it?
A cord is 4 rick, a rick is cut to 16" in length and measures 8foot long by 4 foot tall. A 3/4 ton pickup will squat a little bit with two rick in the bed, and if we are talking good hardwood weigh about a ton.
-------------------- Mycoelf Sterility is a process that can be likened unto infinity, which is a long walk, the closer to the end you start before beginning, the more achievable the goal of infinity becomes. Remember, cleanliness in next to goddessness
      
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RogerRabbit
Bans for Pleasure



Registered: 03/26/03
Posts: 42,214
Loc: Seattle
Last seen: 11 months, 3 days
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Re: My Homebuilt Wood-Fired Steam Generator [Re: mycoelf]
#15260921 - 10/22/11 08:42 AM (12 years, 3 months ago) |
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I constantly overload my 1968 1/2 ton Ford pickup truck with a full cord of wood. I only have a few miles to go from where I cut the wood to our farm, so I just drive very slow and avoid all the bumps so as not to damage the old truck.
Quote:
mycoelf said: I am a retired craftsman and I have to say I am also impressed with your fabrication skills, You are a man of many trades, and that is what it takes these days to surthrive.
Wait until you have to look through a welding hood with bifocals on.  (lame excuse for some of the shitty-looking welds in the pictures) RR
-------------------- Download Let's Grow Mushrooms semper in excretia sumus solim profundum variat "I've never had a failed experiment. I've only discovered 10,000 methods which do not work." Thomas Edison
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Javadog
Continuing along



Registered: 05/03/10
Posts: 7,385
Loc: USA
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Re: My Homebuilt Wood-Fired Steam Generator [Re: RogerRabbit]
#15261031 - 10/22/11 09:33 AM (12 years, 3 months ago) |
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Thank you for sharing RR. This is a wonderful idea. I love the independence!
I agree with Mycoelf, that this is a good time to have many skills.
I have paid more to do some things myself (and knew that this would be the case) because I end up with the experience and the tools when I am done.
You are an inspiration.
Take care,
JD
-------------------- Boyd Rice told my brother that life is a corny pack of freesakes Myco-tek.org
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Wing
The Eye Tyrant



Registered: 04/25/11
Posts: 3,293
Last seen: 5 months, 10 days
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Re: My Homebuilt Wood-Fired Steam Generator [Re: Javadog]
#15261334 - 10/22/11 11:02 AM (12 years, 3 months ago) |
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Wow nice work RR! Very good idea to harness steam for heating and sterilizing.
-------------------- My Old Grow Logs
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mikesethnobotany
Man



Registered: 07/29/11
Posts: 1,267
Loc: Missouri, USA
Last seen: 2 years, 6 months
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Re: My Homebuilt Wood-Fired Steam Generator [Re: Javadog]
#15261443 - 10/22/11 11:39 AM (12 years, 3 months ago) |
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A masterpiece! I applaud your many skills, it takes an outstanding person to do a project like this nowadays. congratulations on the new boiler! Any idea how much fossil fuels you will be conserving using this? Do you get any green credits for doing so?
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RogerRabbit
Bans for Pleasure



Registered: 03/26/03
Posts: 42,214
Loc: Seattle
Last seen: 11 months, 3 days
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Quote:
mikesethnobotany said: Any idea how much fossil fuels you will be conserving using this? Do you get any green credits for doing so?
I spent $6,000 on propane last year and it just went up in price by 25%.
Our farm and home are now 100% free of fossil fuel. Our electricity comes from a bio-mass burning power plant in Kettle Falls, WA, and I do everything else with wood from the forest fire burn area. This means there is zero net carbon increase into the air because the trees are already dead and releasing their stored carbon into the air as CO2. In addition, the design of the combustion chamber reduces almost all smoke by fully burning the wood at high temperature. RR
-------------------- Download Let's Grow Mushrooms semper in excretia sumus solim profundum variat "I've never had a failed experiment. I've only discovered 10,000 methods which do not work." Thomas Edison
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total
Post Office Tyvek Advocator




Registered: 10/03/04
Posts: 11,405
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Re: My Homebuilt Wood-Fired Steam Generator [Re: RogerRabbit]
#15261827 - 10/22/11 01:36 PM (12 years, 3 months ago) |
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Truly awesome RR! Awesome craftsmanship...
Im hoping to get some time to do some shiitake's myself, and have been pondering my own boiler idea... Thanks for the great ideas!
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TranscendingLife
I Don't Need a Life to Live



Registered: 06/09/10
Posts: 21,627
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Re: My Homebuilt Wood-Fired Steam Generator [Re: total]
#15261867 - 10/22/11 01:47 PM (12 years, 3 months ago) |
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Once again, RR stepping it up & rocking it out. Love it!! Eco friendly & extremely efficient. Can't go wrong.
to you good man.
-------------------- AMU: We Quickly Answer Questions Here "One must accept the probability of failure to experience the elation of success." - TranscendingLife “A man of genius makes no mistakes; his errors are volitional and are the portals of discovery.” - James Joyce
      How I Do EVERYTHING      "Your vision will become clear only when you can look into your own heart…. Who looks outside, dreams; who looks inside, awakes."- Carl Jung "Anything that can be done chemically can be done by other means."- William S. Burroughs "You are as dead now as you will ever be" - Seth
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mikesethnobotany
Man



Registered: 07/29/11
Posts: 1,267
Loc: Missouri, USA
Last seen: 2 years, 6 months
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Quote:
I spent $6,000 on propane last year and it just went up in price by 25%.
Christ man! You will be saving huge with this new boiler, probably enough to send all us shroomerites 1Lb. of shiitake each 
Dude, there has got to be green credits for that. In some way-shape-form. You are running a business that has no carbon footprint! I am not fully aware of how the whole green credits work, isn't it a Federal thing? My father is the sustainability coordinator in Lakewood, CO. and he is always preaching talking about those green credits... maybe that is just a Colorado/California thing? Seems to me like you should be receiving government incentives for your enviro-friendly farm.
It amazes me that so many people out there think that going green is so expensive. Yet here is a perfect example of a green type project that is saving you thousands of dollars in the long run.
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woodland_jewel
In den Gärten Pharaos


Registered: 09/07/11
Posts: 401
Loc: Penna
Last seen: 1 year, 6 months
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RR, you are the f'in MAN! That's amazing!
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RogerRabbit
Bans for Pleasure



Registered: 03/26/03
Posts: 42,214
Loc: Seattle
Last seen: 11 months, 3 days
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Quote:
mikesethnobotany said: I am not fully aware of how the whole green credits work, isn't it a Federal thing? My father is the sustainability coordinator in Lakewood, CO. and he is always preaching talking about those green credits... maybe that is just a Colorado/California thing? Seems to me like you should be receiving government incentives for your enviro-friendly farm.
I hold elected office up here as a conservation district supervisor. Scroll down on that page to see a short writeup they did on our mushroom farm. That article was written before the bio-mass steam generator went in.
Rather than accept readily available grants, I did all this on my own nickle. Personally, I think it sets a bad example for people to expect to get paid for nothing other than doing the right thing.
There's more than meets the eye here. I designed and built all this as an engineering and research/development project. The Dept of Natural Resources and the Forest Service are removing thousands of tons of overgrowth from the forests to improve their health and prevent super fires. I have come up with procedures and supplements to profitably grow gourmet mushrooms on the Douglas fir, Ponderosa pine, lodgepole, Tamarack, etc., which are being thinned, all of which are currently going to the power plant where it's piling up in huge mountains because they can't burn it fast enough. I intend to approach investors, as well as the area tribes to get interest and funding for a major facility, based on the research and systems I've developed here.
We have unlimited land, people looking for work, and mountains of free woodchips to power an industrial boiler plant and grow the mushrooms on. RR
-------------------- Download Let's Grow Mushrooms semper in excretia sumus solim profundum variat "I've never had a failed experiment. I've only discovered 10,000 methods which do not work." Thomas Edison
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waixingren


Registered: 03/14/05
Posts: 2,644
Loc: SW Florida
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Re: My Homebuilt Wood-Fired Steam Generator [Re: RogerRabbit]
#15263568 - 10/22/11 08:53 PM (12 years, 3 months ago) |
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good stuff rr
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SOUTHERN
NAIL DRIVER



Registered: 03/29/09
Posts: 846
Loc: south
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Re: My Homebuilt Wood-Fired Steam Generator [Re: RogerRabbit]
#15263581 - 10/22/11 08:55 PM (12 years, 3 months ago) |
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Nice work RR. your work is always planned and profesional... With fuel prices today, it doesn't make since not to look for better options..
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