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  1. #1
    Join Date
    Nov 2006
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    Darwin HowardSprings
    Age
    52
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    41

    Default Diesel Powered FURNACE build

    Disclaimer > do not try this at home , or atleast say " WATCH THIS " to a mate before hand , so he can upload your error in judgment too Utube , so the HOLE WORLD can laugh at you , ( just remember i said DONT do it , so dont sue me )

    looked in the metal working section ,????? no real section for Furnaces ???? so since you have to make an object before you can cast it , CNC is a good place , and every one with a CNC wants to turn there MDF object into metal?


    for the last few weeks ive been collecting parts/ materials for the next corner of my shed , the foundry
    ive been stalking some Furnace Forums for ideas ,
    and decided im gonna make one

    for the furnace i went with a size #10 crucible , 200mm high 160mm wide , holding 2.4lt of the glowing stuff
    so based on the size of the crucible i drew this up , with a 20mm gap between the crucible and the wall of the furnace
    furnace3b.JPGfurnace3a.JPG
    the " hot face " i selected is called "Shiracast 160AR" about $66 a bag from "the fire brick company " , its good for 12months at 1600c temp (cast iron poring temps)
    i also purchased KIOwool , a ceramic insulation rated at 1250c to insulate the hot face ,. and all that will go in a cut down 40 gallon drum

    so last night i turned the cad drawings inside out , so i can machine up some " molds " , they will be 50mm slices , milled from polyurethane foam , then glued back together , and finished with polyurethane glue

    Drawing4STEP.zipDrawing4DXF.zipFurnace4.JPG

    then using a" speckle gun " i plan on building up the surface until its 30mm thick , the last 10mm will have chopped up carbon fiber added to help reinforce it together



    for the HEAT i opted for diesel , LPG wont get up to a high enough temp , and waste oil ( better temp ) is too hard to get too burn stable
    i went for a 140psi fuel injection pump rated at 200lt per hour , a high pressure fuel regulator , and a " water misting " head ( 0.3 square mm hole ) , it should burn about 4.5lt of diesel per hour , inside a 50mm diameter tube , with a blower for the air

    i just got the misting head up to pressure , with rubber hose , for a test of "atomization " and fuel flow , and will have to replace the fuel tube with metal and set up the burner properly , but it spat fire , first go

    full mist.jpgfire.jpgJet.JPG

    so this is what im up too
    how come a 10mm peg dont fit in a 10mm hole

  2. #2
    Join Date
    Dec 2005
    Location
    Canberra
    Posts
    490

    Default

    Hummmm.... 20 plus kilos of molten iron....can I suggest a small crane for safety....

  3. #3
    Join Date
    Nov 2006
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    Darwin HowardSprings
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    Quote Originally Posted by Master Splinter View Post
    Hummmm.... 20 plus kilos of molten iron....can I suggest a small crane for safety....
    nar employ a suicidal bloke to do it for you ? i don't want to get within 3 foot of 2.5lt of molten iron , it will give you at tan at 10feet

    im building this to withstand iron temps , but brass will be the hottest ??1100c( i keep telling my self ) , to the brim with brass is 18kg , (#10 crucible ), a 2 person lift and pore "crucible plucker"

    will only go to 900c with aluminium most of the time

    with the left over materials i will make a small Number4 sized one as well ( 0.75lt ) , and in time a #40 crucible would be nice at 6.7lt or 50kg of brass , would need a crane for that one , or design it as a tilting furnace
    how come a 10mm peg dont fit in a 10mm hole

  4. #4
    Join Date
    Jan 2010
    Location
    Bundoora, Melbourne.
    Posts
    212

    Default

    I think you've been sniffing too much saw dust. Nonetheless, don't let me stop you, enjoying this so far.
    -Scott

  5. #5
    Join Date
    Mar 2009
    Location
    Midland WA
    Posts
    4

    Default

    Back in the old days I used to smelt gold in a diesel furnace, all you need to add is a fire brick tub and a blower vac. You'll have the noise of a 747 on take off and more heat than you'd ever need. Fantastic bit of gear the diesel furnace makes me feel all happy inside.

    Ian

  6. #6
    Join Date
    Feb 2008
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    NOWRA
    Posts
    9

    Default

    Awesome project. Look forward to seeing it and some projects when done. You'll probably get some jobs off here too, be nice to get rough casts done and then machine them clean on certain parts.

  7. #7
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    Nov 2006
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    did a bit more on it today , i went back to the oil instead of the mist sprayer for cooling the bit ?/ quicker to set up on a 10min cut , and my compressors in my van , and it was raining , and i cant think of any other excuses

    i cut out some " spinners " from 3mm aluminium , these spin the air inside of the "blowers tube "
    spincut.jpg

    also cut out an aluminium plate , that the 2 blowers , fuel regulator & switches will bolt too

    FanHoldCUT.jpgFanPlateSpinEPS.zip
    and tapped out the 6mm copper tube , and tapped it out so the "jet " screws onto the the end of it
    blowerMade.jpg

    a number 10 crucible they say only needs 4.5lt per hour of diesel , at a 14:1 oxygen / fuel, with 20% oxygen in air , its only 315lt of air per hour , a lot less than i thought , my big blower might get turned into a sawdust extractor


    ( this new upgrade is giving me the ##### , connection keeps dropping out on down loads , have to wait 5min after clicking "reply to thread " before i can type , ??? i just dont like it, the up grade is slower than the original ?? , yes my connection is crap at 2kbs , but thats a mobile telstra broadband in my area ( over sold band width ) and the new cable roll out wont come to Darwin at all )

    it takes so long , ive managed to draw up the next part in CAD while i waited
    how come a 10mm peg dont fit in a 10mm hole

  8. #8
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    Feb 2008
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    NOWRA
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    Great work!

    Second ya on the new website. Not having the same issues but just seem clunky and slow.

  9. #9
    Join Date
    Jun 2008
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    Victoria, Australia
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    74
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    5,080

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    Hi SawDustSniffer,

    Great project, I think oil fired is a good way to go, cheap to run and plenty of heat. Mine is LPG fired with forced air.

    I got a chance to see Nick Muller's oil fired furnace in action a few weeks back, when tuned and running it was nice and clean, (no smoke)

    There are some threads in the Metalwork forum including some with video's of NIck's setup.

    Good luck with the project, I'll be watching with interest.

    Regards
    Ray

  10. #10
    Ueee's Avatar
    Ueee is offline Blacksmith, Cabinetmaker, Machinist, Messmaker
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    Um....where the blazes did this forum spring from...did i miss something?
    After all my research i would go with Ray and say waste oil is the go, lots of good info on the net, cheap, hot and easy. Also no so dangerous if you spring a leak.....for simple UMO plans try here: melting metal in a home foundry, backyard metalcasting, metal casting
    Are you going to use a steel crucible? My old flower pot furnace ran on coke, but i got better results with a bit of 250mm steam pipe on its end in the forge. I could also never get the steel crucibles to stay liquid tight, they would always spring a leak....bad welding i'm sure.
    Watching with great interest
    1915 17"x50" LeBlond heavy duty Lathe, 24" Queen city shaper, 1970's G Vernier FV.3.TO Universal Mill, 1958 Blohm HFS 6 surface grinder, 1942 Rivett 715 Lathe, 14"x40" Antrac Lathe, Startrite H225 Bandsaw, 1949 Hercus Camelback Drill press, 1947 Holbrook C10 Lathe.

  11. #11
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    Mar 2009
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    Midland WA
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    Quote Originally Posted by SawDustSniffer View Post
    ( this new upgrade is giving me the ##### , connection keeps dropping out on down loads , have to wait 5min after clicking "reply to thread " before i can type , ??? i just dont like it, the up grade is slower than the original ?? , yes my connection is crap at 2kbs , but thats a mobile telstra broadband in my area ( over sold band width ) and the new cable roll out wont come to Darwin at all )

    it takes so long , ive managed to draw up the next part in CAD while i waited


    What operating system are you using. If I use my desktop (windows Vista) it locks up etc etc, but if I use my laptop (windows XP) all seem ok.

    Just remembered I have a miniture furnace I inherited from a reli, I'll have to fire it up to see if it works and take some pics. It uses a reversed vacuum cleaner for air.

    Ian

  12. #12
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    Nov 2006
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    managed to get a few good hours out in the shed tonight

    i knocked up a HDPE , round to square converter , yer HDPE aint the best but i had some , looks like ive found something to cast in aluminium already
    machining HDPE with a strong wind is not good , shed is now full of fake snow , very festive

    square.jpground.jpgSquareCAD.ziproundCAD.zip

    so then i put it together

    at the moment its got o.15mm jet in it , this week some 0.3mm jets will arrive , with the 0.15 jet it runs 1.125 lt per hour , im hoping 0.3mm will give me just over 4lt per hour ( some ones got to try it
    left.jpgtop.jpgright.jpgbottom.jpgend.jpg


    yer looked at waist oil , and saw there burners , with heaters that get too hot and clog , the filtering , have to start them on LPG , who knows what the mechanic pores in that drum , a couple of liters of synthetic oil and it will be smoking like an Indonesian child , yes it will get hotter , but my furnace im making will only last 12months at 1600c , iron melting is not a priority , i just think diesel is just easier , and at 4.5lt per hour , affordable with the lest amount of stuffing around

    the only thing not in these photos is the 140psi fuel pump , its in a fuel drum , fan speed controller + pump switch and shut off tap
    i looked at the web sites at burners , and scratched my head , just spray the fuel down the pipe , so thats what ive done , my own plans

    i splurged and got a clay graphite number 10 crucible
    how come a 10mm peg dont fit in a 10mm hole

  13. #13
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    Nov 2006
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    was about to spit the dummy about being moved , so before i did i looked where i was moved too ,
    cool a new forum page just for me , i wont be complaining
    i guess now im not in the "CNC section " i dont have to post photo's of cutting and cad files i used , ( i still will )

    cheers ken
    how come a 10mm peg dont fit in a 10mm hole

  14. #14
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    Nov 2006
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    so you guys seam to think waste oil is hotter than diesel ? , i pulled this off a different site


    Natural Gas.....1,030 BTU/cu ft
    Propane.........2,500 BTU/cu ft
    vegetable oil 120,000 BTU/gal

    gasoline......125,000 BTU/gal
    waste oil.....125,000 BTU/gal
    Kerosene.....135,000 BTU/gal
    diesel.........138,500 BTU/gal

    hard coal 13,000 BTU/lb
    soft coal 12,000 BTU/lb



    how come a 10mm peg dont fit in a 10mm hole

  15. #15
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    Nov 2006
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    ive started on the foam mold for the furnaces body

    i put the glue a bit too close to the edge on the first 2 layers i glued together , there is still a round peace to go on the " top " (bottom ) but i will glue that on last so its easier to compress the sheets together with sheets of MDF while the glue dries
    furnaceFoam.jpg
    how come a 10mm peg dont fit in a 10mm hole

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