Alternative Energy Source
replacing propane/natural gas/fuel oil.
On Dec. 3, 2007 I began a new experiment on the home farm.
I
installed a corn burning hot water heating outdoor furnace to heat the
house. The furnace is a commercially manufactured corn burning
water heater. It has the following specs:
Corn capacity: 8
bushels There's a lot of difference in corn types. Some
burns clean with little ash, some burns poorly with lots of ash.
I'm still sorting out which corns burn best and why.
Water capacity: 27
gallons ( I am using soft water that is softened using a
household water softener). Using no antifreeze or rust inhibitor.
Electric: 110
volt. I used 3/12 with ground. I have two possible hot
wires and one common ground plus a neutral.
Distance from house:
approx 70ft....mounted alongside the driveway. All outside pipes
and electric wires are buried underground.
Water Pipe used: Pex
tubing....1¼ in diameter or 1in diameter cpvc (in the
house only). The undergound 2 pex lines (inlet & outlet) were
wrapped with fiberglass insulation and inserted into a 6 in black
plastic non perforated field drain tile and buried about 3 ft
deep.
Fittings: Watts 'o' ring
connector fittings, elbows, tees, etc., or standard plumbing cpvc
fittings. I love the Watts fittings and the cpvc is easy to work
with too.
Valves: Mostly cpvc ball
valves. Some brass or stainless ball valves with 1in pipe
threads on either side of the pump.
Pump: 42 gpm pump
110Volt 1 inch inlet and outlet. Its mounted at a
lowest point in the basement about 80 ft from the tank and sucks
hot water from the tank then goes to 2 heat exchangers installed in the
2 furnace plenum. The original furnace blower runs continuously
24 hrs. per day and extracts the heat from the water. The
slightly cooled water is returned to the tank. The distance the
hot water travels from the pump, through the house, and back to the
tank is approx. 200 ft. It looses about 10 degrees F. from
hot outlet to cooler inlet at the tank. This is a non pressurized
water system. The whole water system can be drained in the
basement near the pump. One pump is very adequate.
Capacity: Manufacturer
claims 200,000 btu burner output. There is some heat loss
mostly at the burner door and flu pipe (6 in dia).
Quantity corn used at full
output. 250 lbs. per day approx.
Cost comparison to
propane. 91000 btus/gallon propane, 9000 btu's per lb. of
corn (takes 10.1 lbs corn to = 1 gallon propane for btu's
). Propane price is $2.00 per gallon and corn is
approx. 9 cents / lb. Therefore burning corn is equivalent to
burning 90.9 cent propane or less than half the cost of burning
propane. Corn at $10.00 per bu and Propane at $2.00 per gallon
would be approx. equal in cost/btu output in this situation.
Management: Burning corn
outside takes some management. You have to 'poke' the
ashes/clinkers loose from the burning pot 3 or 4 times per day.
You have to empty the ashes/clinker box once per day or
two. You have to 'scrape' the soot down from the water tank
above the fire pot 2 or more times per day. The soot prevents a
good heat transfer to the water and acts like an insulation barrier.
You may have to add water every couple of weeks. I left
mine unattended for about a 36 hour period and it was heating at at
less
output with the ashes coving the burner pot totally and needed to be
emptied to bring it back up to full output. My house is actually
two houses connected by a great room with two furnaces. This
year the burner has run at the max for most of the
time since I started it. Heat controls in the house is
not
needed. My wife loves the heat, it's continuous and the air
is always slightly warm coming from the vents.
Comment: I like the
outside burner....the fire is away from the house...less fire
hazard, the mess is also outside the house, the ashes are
outside the house and if mounted near the driveway is easily accessible
by vehicle for refilling with corn. I bag my own corn and
put it on pallets and bring a pallet when needed and fill the bin once
per day. I have a skid steer with forks and place the pallet next
to the corn burner and it's quite easy. I cover the pallet with a
small tarp to keep the bags dry. My next project is to put up a
bulk bin with gravity feed to the corn burner. One 125 bu bin
of corn should last a month or more. I'll have to fill it with an
farm auger and haul it in bulk with a truck.
Another thing I've done....purchased wireless thermometers and
installed them at the burner, the pump, the heat exchangers, and in
certain rooms in the house. This gives me insight into what's
happening in the system and I can always tell when something has
changed... and might lead to a problem.
I made a expanded metal base and mounted above the fire pot and put in
wood to see what happens. Guess what, the burning of the wood and
corn together, actually takes some of the heat away and cools the
output water a few degrees. There is not enough
Oxygen to support corn and wood burning together. I believe the
combustion fan is rated at 68 cfm.
Carbon neutral....the idea is to approach carbon neutrality when
heating, driving, farming, etc.. Carbon that is sequestered
in the top portion of the soil that can be used to produce renewable
fuels is considered carbon that is neutral. Carbon being
brought up to the surface put into service as is carbon from fossil
fuels that were deposited millions of years ago and now being used is
not carbon neutral.