Pyrolysis boiler with own hands

Pyrolysis boiler is one of the most modern and economical types of heating units. To operate such a boiler is suitable for a variety of solid fuels - from firewood and pressed granules to peat and household rubbish.

The only significant drawback of such equipment is its high cost. But if you wish, you can cope with the manufacture of the boiler yourself. To do this, you need to thoroughly understand the assembly schemes and have the skills to work with welding equipment.

Table 1. Pyrolysis, gas-generator boiler. Parameters at different powers

Parameters	Unit.	15-25 kW	20-30 kW	40-50 kW	80-100 kW
Heating capacity	kW	15-25	20-30	40-50	80-100
The volume of the load chamber	m3	0,13	0,15	0,22	0,52
Working fluid pressure( not more than)	MPa	0,3	0,3	0,3	0,3
Operating water temperature. Maximum / Minimum	0С	90/65	90/65	90/65	90/65
Efficiency at the fuel humidity: 20% / 40%	%	90/82	90/82	90/82	90/82
nominal underpressure behind the boiler	Pa	25	25	25	25
temperature outgoing gases	0C	140	140	140	150
power consumption	W	40	40	90	180
supply voltage	In	220	220	220	220
chimney diameter	mm	194	200	200	219
Heated area( approximately)	m2	To 250	To 300	To 500	to 1000
Maximum Draw Lengthin	m	0.45		0.45 0.58 0.92
Dimensions length * width * height	mm	810/740/1130	810/740/1220	950/760/1350 1300	/ 1030/1440
Weight	kg	350	400	450	650
Fuel	-	Firewood, fuel briquettes	Firewood, fuel briquettes	Firewood, fuel briquettes	Firewood, fuel briquettes

How does the pyrolysis boiler work?

Pyrolysis principle is based on the operation of the boiler, the essence of which is the thermal decomposition of solid fuel at high temperature under artificially created oxygen deficiency. As a result, the fuel smoldering, decomposing into a solid residue and pyrolysis gas. The resulting gases also burn, which increases the heat efficiency of the equipment and makes fuel consumption more rational.

An additional advantage of the heating boilers in question is environmental safety. In the process of pyrolysis fuel combustion, harmful components that are released are mixed with carbon dioxide and disposed of. As a result, smoke that does not contain carcinogens and other harmful substances is emitted into the atmosphere. This feature allows you to heat the boiler even with rubber, chipboard chips and other similar materials.

boiler Important! The amount of impurities such as rubber and polymers should not exceed 20% of the total amount of fuel.

The operation of pyrolysis boilers consists of 4 main stages.

1. In the first stage, the fuel is further dried and decomposed into a solid residue and gases.
2. In the second stage, pyrolysis gases are burned.
3. In the third stage, the flame is blown and the heat returns to the fuel, which contributes to the release of additional heat.
4. In the fourth stage, the remaining combustion products are discharged through the chimney.

Having understood the peculiarities of the boiler operation, we proceed to its manufacture. Let's start by preparing the necessary materials and tools.

Set for operation

1. Sheet metal with a thickness of 0.8 mm.
2. Fireproof bricks.
3. Temperature sensors.
4. Lattice grate.
5. Pipes with a diameter of 32 mm, 57 mm and 160 mm.
6. Profiled pipes in quantity of 2 pieces.
7. Ash door.
8. Door for the fuel chamber.
9. Fan.
10. Flexible fired wire.
11. Bulgarian.
12. Grinding wheels.
13. Welding machine.

How to make a pyrolysis boiler

Before starting to make a boiler, read some helpful recommendations. If they are observed, the finished equipment will be as productive, efficient and economical as possible.

Useful recommendations

1. The system needs to be completed with a valve to regulate the flow rate of the coolant.
2. To increase the heat transfer, the coolant pipe should be made curved, for example, in the form of a coil.
3. The fuel loading opening must have a rectangular shape. In this case, the door of the hole should be completed with a steel seal for sealing.
4. To control the intensity of incoming airflow, the system is equipped with a limiter.

The first step. We cut out the walls of the boiler body from sheet metal in the amount of 4 pieces. In the front wall we cut out the holes for the combustion chamber and ash pan.

The second step. Cut openings for pipes and smoke exhaust.

The third step. We join together all the metal walls, except for the rear. To do this, we use a welding machine. Carefully sand the joints between the sides of the future boiler.

Fourth step. We collect the heat exchanger of the boiler in accordance with the presented scheme. We weld the pipes. The

The fifth step. We insert the heat exchanger into the boiler body. We are convinced of tightness of connections by means of the compressor. In the absence of leaks weld the rear wall of the case.

The sixth step. Install the grid grate. It will divide the boiler body into 2 chambers. In one( bottom), the load will smolder, in the second - the gases will burn. The lower chamber is completed with an air duct, and afterwards we impose fireproof brick on each side.

The seventh step. Mount the doors of ash chamber and firebox. They should fit snugly against the body.

The eighth step. Install the assembled boiler on a pre-laid brick foundation.

The ninth step. We connect the chimney. It is recommended to wrap the smoke exhaust pipe with mineral wool for insulation.

The tenth step. We connect the water circuit to the unit.

Eleventh step. We install the air pump.

In addition, the boiler can be automated by installing a system of temperature sensors and regulators. They will control the intensity of the air supply.

Safety instructions

When installing a self-made boiler, we observe the following important rules:

• for the installation of the heating unit, it is necessary to allocate a separate boiler room;
• in the boiler room it is necessary to equip an efficient ventilation system. The minimum area of ​​the airway is 100 cm2;
• the distance between the unit and any other surfaces and objects should be greater than 20 cm;
• , before laying the boiler, lay a steel sheet with a thickness of at least 3 mm on the floor;
• boiler is installed on a pre-arranged brick or concrete base;
• smoke extraction pipe must be insulated with high quality. Without heat insulation, the formation of condensate, soot and other troubles will be more intense. This will negatively affect the efficiency of the equipment and its service life.

At the end, the boiler efficiency is checked. To do this, it is enough to make a test load of fuel. If the exhaust smoke does not have an odor, then the efficiency of the boiler is OK and it can be used to heat the house without any fear.

Than to heat a pyrolysis boiler?

Fuel types

For heating of the pyrolysis boiler you can use:

• firewood;
• peat in briquettes;
• anthracite;
• wood pellets and briquettes;
• brown coal;
• coke.

The listed fuel types differ in caloric content. The efficiency of the unit depends directly on this indicator. The use of less caloric fuel can reduce the efficiency of the boiler by 30% or more.

More often for a furnace pyrolysis boilers use briquettes and pellets. Briquettes can be made of wood, straw and peat. Ideal option - briquettes, made by the method of pressing. The same briquettes, which are made from sawdust, it is recommended to use only in combination with brown coal or wood.

For the production of pellets, wood or straw can also be used. The material is pressed like briquettes.

Often used for the burning of pyrolysis boilers are firewood. Important! To ensure maximum efficiency of the equipment and reduce fuel consumption, wood should be used with a moisture content of no more than 20%.

In general, when choosing fuel, you should take into account the characteristics of the terrain in which your house is located. If you live in a forest environment, the most appropriate option is the use of firewood. Residents of the same steppe strips, as a rule, are more profitable to heat coal.

If any fuel is available in your place of residence, choose the most caloric. This will ensure the highest efficiency of the equipment at the lowest flow rate.

Boiler specialist's advice on

Let's see what professionals say about the choice of the optimal type of fuel.

So, when burning wood, a lot of smoke will form. To get rid of the attendant inconvenience, at the edges of the load you need to stack logs of a larger size, and put a small kindling in the center.

In densely populated areas, it is recommended to refrain from using peat,in the process of its combustion, a large amount of carbon dioxide is released and various large particles are emitted into the atmosphere, which is unlikely to appeal to neighbors.

For effective use of anthracite, a strong focus is needed. The power of the pyrolysis boiler is usually not enough to completely burn such a fuel. To reduce costs, remove large fragments from the ashes and use them again.

Thus, knowing the skills of welding and following the recommendations above, you can independently produce an efficient, reliable, safe and economical pyrolysis boiler.

Good work!

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