Hi Guys...
A brief report back for the copper coil heatex addition....
Did the first run with it yesterday afternoon, the previous day's installation was cancelled due to lack of interest, and a mate arriving from a neighboring city... He needed some wheel blanks cast for a belt grinder he is starting to build... Needless to say, the attraction of playing with the furnace and sloshing around a few liters of red hot, molten aluminum won out over cutting slots in pipes with an angle grinder in the midday heat.... The casting went well, no toes and fingers incinerated, a half dozen or so 80mm wide blanks of varying diameter were produced, he was a happy chappy at day's end...
Back to the heatex... After about an hour of cussing, sweating and climbing up and down ladders, I had the unit installed in the flue. It wasn't a major task actually, just awkward, most of it ladder and angle grinder work, with a tiny little bit of drillery, tappery and weldery to fix everything into place... At the end of the job, I have a pretty mundane looking stack with a bolt on square inspection cover type of thing... The coil resides behind the cover and can be pulled out of the system by loosening a couple of 1/2" pipe fittings and reconnecting what is there... Strangely, and quite impressively, there is not much need to install the cover over the 4"wide by 2ft odd slot in the up-pipe... for tits and pickles, I wound the burner up with the cover open to see what it looked like, expecting gouts of flame and general mayhem... Nothing happened... It was as if there was a glass cover over the slot, flames passed the rather long opening in a neat spiral, following up the riser... Kinda spooky, to say the least... Needless to say, I wound it up a couple more times to show the ladies of the house, all were most impressed, so it wasn't a fluke, clearly there is plenty of draw on the old pipe chimney to do the job!! But as usual, I digress...
As to the actual heating side of things, it was also quite interesting... We started with 350L or so of 20 to 25C water, hit the on button and I took some measurements and readings...I was amazed...
The little circulation pump is whipping the water through the system at quite a rate, to get a nice even heat up of the storage tanks.... If I set it to "low" volume setting, I tend to get a large "plug" of hot water moving through the system, making it difficult to estimate turn off time (there is no auto control on this thing, its fully 100% manual)...
Back to the readings... into and out of the original heatex, I am getting a temp gradient of 1 to 2 degrees C... from there, it flows into the coil which is in the path of the exhaust flame from the original heatex. Normally, a heat run would take between 1.5 and 3 hours, between 1.5 and 5L of fuel, depending on type fuel, residual temperature of heat store, air temperature, phase of the moon and how many black cats were sacrificed to the dark engineering arts.... The previous days run used around 3 hrs and 4L of waste gunk to get it to the target temp of 50C...
Day temps were similar to the previous day, start temps only a few degrees different, run time was DRASTICALLY reduced... Inlet/outlet to the copper coil had a gradient of around 10C, way more than I was expecting.... The total run was only 45mins and consumed only a little over a L or so of fuel... Target temp ended being 10% higher, 55C, just because I took me time turning off the system while I picked up some of the tools I left strewn around..... I LIKE IT!!
This does of course bring up another problem....with this amount of heat recovery (if it carries on like this and it wasn't my senile imagination), I will need to put some sort of rather large, obnoxious, intrusive siren type temperature alerting mechanism on it... Lest I meander thru life placidly to return to a little molten pool of copper......
Keep it heating...
Cheers
Ed
(Of course the crappy quality mandatory pair of cell phone pics follow...)