Heat exchanger for a brick furnace

Few things are as important as a dependable heating system for keeping our homes warm during the winter. Traditional brick furnaces are still a popular option for many homeowners because of their dependability and efficiency. It can be difficult to maintain effective heat distribution while consuming the least amount of energy, though. Heat exchangers can help in this situation by providing a solution that improves brick furnace performance and encourages energy efficiency.

In order to properly distribute the heat generated by the furnace throughout the house, a heat exchanger is a device that transfers heat between two or more fluids. Heat exchangers in brick furnaces function by absorbing heat from combustion and transferring it to the water or air that circulates throughout the home. By maximizing the furnace’s heat output, this procedure makes sure that the entire house is adequately heated.

The capacity of a heat exchanger to increase energy efficiency when used with a brick furnace is one of its main advantages. Heat exchangers help homeowners get more use out of their heating systems while using less energy and paying less in utility bills by capturing heat that would otherwise be wasted. As a result of reducing the carbon footprint associated with heating, this helps the homeowner both financially and environmentally.

Additionally, the quality of indoor air can be improved by combining a brick furnace with a heat exchanger. Heat exchangers serve to lessen the need for forced-air systems, which occasionally result in uneven heating and the spread of dust and allergens, by effectively distributing heat throughout the house. This helps to create a more cozy and healthy indoor environment, which is especially advantageous for people who have allergies or respiratory issues.

All things considered, adding a heat exchanger to a brick furnace system gives homeowners a useful and affordable way to raise indoor comfort levels, boost energy efficiency, and improve heating performance. Installing a heat exchanger can save money and help the environment in the long run, regardless of whether you’re building a new house or upgrading your current one.

Heat Exchanger Type	Brick Furnace
Efficiency	High

Types of furnaces, and is everything suitable for heating the house

Numerous variations exist, each suggesting distinct features and functionalities. Because stoves are the smallest and easiest devices to arrange with your hands, they can only be used as hobs. Bigger buildings are used for heating. However, they have always been the most well-liked and are still in use in areas that are not yet agricultural: huge furnaces that heat the home, livestock cookers, bread bakers, and dried fruit makers.

Modernization of such structures occurs to this day. The fact is that before the houses were built small, often for one or two rooms, with low ceilings. Such a layout of the house allowed not to create an extensive heating system, the heat of the furnace was enough to warm it entirely. But such a drawback as the concentration of warm air at the top of the room and directly near the furnace does not allow you to warm up modern housing qualitatively. Understanding that this defect needs to be corrected, people came up with a water heating system in the house where the boiler is a heat exchanger mounted in a brick furnace. It is able to warm up the whole house with qualitatively, thanks to the circulation of hot water through the pipes to convectors.

The principle of operation of the furnace with a heat exchanger

After cooling, the water in a closed system enters the heat exchanger and reheats. You can perform this type of heating with your hands, particularly if it is made again. Redoing the finished stove already presents a number of challenges. The primary challenge lies in the fact that the heat exchanger needs to be installed within the pre-existing furnace design. Its dimensions must match the furnace’s design to guarantee the right amount of heating.

Two major categories exist for brick stoves:

• holding heat;
• Quickly dead.

According to the first option, the stove is constructed in a way that allows for prolonged heating. However, the furnace can maintain the house’s temperature for a considerable amount of time after it is fired up once a day, so cooking is still possible even in the absence of fresh firewood. Cooling stoves are good at conducting heat; they heat up fast and provide energy to the room, but they need to be constantly monitored.

Cons of water heating

Any furnace constructed by a skilled craftsman or yourself will have a heat exchanger that shortens the furnace’s heat-retaining duration. She needs to warm the water in the system as well as her surface. It is important to consider this when building. Selecting the appropriate liquid to fill the system is crucial, particularly if the house is unoccupied during the winter. Water can freeze in the winter and cause failure if it is decided to pour water into the heat exchanger and pipes, which is a feature of water heating systems.

Experts recommend selecting unique non-freezing liquids.

When building a heating system, their cost will have a major impact on the overall budget; however, their installation does not require the use of particularly thick pipes, and the batteries that are available in construction stores are not the same as those that were previously used. Their form and the amount of fluid needed for the entire contour’s operation are intended to reduce fuel expenses.

Optimizing insulation and heating is essential for creating an energy-efficient home. The heat exchanger in a brick furnace is essential to reaching this objective. This clever device greatly increases the efficiency of the furnace by using the heat it produces to warm the surrounding air or water. It reduces heat loss and maximizes energy utilization by transferring heat from exhaust gases to incoming air or water, which eventually results in lower heating costs and a more comfortable living environment. A heat exchanger for a brick furnace can be a sustainable way to improve warmth and energy efficiency in any home, provided it is installed and maintained properly.

Types of registers, features and advantages

Heat exchangers come in a variety of designs. They are also either custom designed or produced in factories. All technological subtleties are included in the initial version; however, the stove must be designed for a particular heat exchanger. In the event that the heating system has already been designed and understaffing is required, the current furnace design must be taken into consideration. If you are proficient in gas welding, you may attempt to create a heat exchanger on your own; if not, you should consult an expert.

Two main types of registers structure applicable to water heating systems are distinguished. They can be made of tubes, in the form of a coil, according to which the liquid circulates or from steel plates. Trouble heat exchanger of the furnace equipped with water heating has a large warming area, which improves its characteristics. But a significant minus is the ability to boil water with an intense firebox. This can be avoided using pipes of larger diameter. Also, such a problem can happen to water heating if the liquid circulation is insufficient. This happens due to improper installation of the system, installing the heat exchanger with your own hands without proper experience and qualifications.

The problem is easy to solve: all that needs to be done is outfit such a "boiler" with a pumping station that will supply liquid through water tubes, keeping it from stagnating. As a result, the heat exchanger won’t be able to heat it to the point of boiling, the batteries themselves will never get cold, and the entire house won’t cool down.

Trouble heat exchangers are used in furnaces that have stoves attached to them in addition to water heating stoves at home. Because of its design, you can install the register inside the oven without sacrificing the quality of the hob’s warming. Further tubes are welded to it if there is no such need. This amplification will contribute to the heating system’s increased efficiency. This form’s drawback is how difficult it is to clean. You must routinely check and clean the water heat exchanger because soot gets into the pipes and clogs them, making it harder to cross-country.

This is less of an issue in a steel sheet design. However, its sole application is in furnace heating. In any scenario, preventing boiling water in a water heating system will aid in the development of a register that is at least four centimeters thick. It can also be modified for the hob if trumpeters are used in place of the regiment’s upper shelf.

What to take into account during the construction of the furnace

Different constructions exist, but the heat exchanger cannot accommodate them all. Popular channel systems, for instance, just do not have a location designated for boiler adaptation. Such a stove is simple to make by hand, but it won’t be able to accomplish everything that is expected of it.

A chamber stove would be the most effective choice. The oven, around which the heat exchanger is built, can be portrayed by the camera. As a result, the furnace’s design has been modified to accommodate cooking, water heating, and home heating. Warm air from the register travels to the convector, warming it throughout the height, after passing through the camera and providing the necessary thermal energy. Because it can safely heat the entire room, the convector is positioned over the height of the furnace, complementing water heating.

A brick furnace with a heat exchanger is constructed similarly to a simple furnace. You can construct it by hand. The content is unique and necessary. Heat-resistant red brick is typically used as a solution; in areas where temperature influence is greatest, chamot is used instead. The best basis for the solution is clay.

Building must always begin with waterproofing and the foundation. Since a brick stove is a heavy appliance, it requires a sturdy foundation. Accuracy and action verification are necessary in masonry. You must also reinforce and create with a dressing any areas where the brick will not be looped (seduced, males, holes for the height of the ash, etc.).

When constructed in accordance with all regulations, the furnace will serve as a great foundation for water heating, heat the entire house with little firewood use, and last for many years.

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DIY stove or heat exchanger for a furnace

Finding out what influences its effectiveness is a prerequisite to selecting the best heat exchanger for the furnace and the most effective design. It is possible to identify the following key elements that influence its capacity for heat transfer:

• The area of ​​its surface, the larger it is, the more energy it is transmitted;
• thermal conductivity of the material from which it is made;
• temperature difference – the greater it, the more energy is transmitted.

The following conclusions can be made in light of this:

1. The design of the furnace boiler or heat exchanger for the furnace should be such that the area of ​​its contact with the medium with a high temperature (flame or hot gases) was maximum. Based on this, it can be concluded that the constructions of boilers of the same sizes made of pipes will be more effective than the same – from sheet metal. Although the frequency of the location of the pipes and their diameter matters here. In order not to guess, you just need to calculate the total area of the surface of the heat exchanger, which will contact the hot environment – the more it will turn out, the better. Even a schoolboy can do this.
2. For the manufacture of heat exchangers, it is necessary to use materials with good heat transmitting ability. But besides this, they should withstand the temperature and aggressiveness of the environment from which it will take heat (fuel or chimney). From available materials, it can be steel or cast iron. Although the steel is most often used: in the form of pipes or sheet. This explains both the presence of a wide range of her profiles and thickness, and the relative simplicity of working with her: it is easy to weld or bend to obtain the design of the selected shape. On the other hand, cast iron is more resistant to an aggressive environment, but this is a fragile material, does not tolerate strokes and sharp changes in temperature, therefore, only ready -made sections can be used to make a heat exchanger. One of the examples of such a heat exchanger may be its design made of sections of an ordinary cast -iron radiator, discussed below.
3. To ensure reliable natural circulation of the coolant, the difference in the temperature of the coolant at its input and output, the greater it is, the better the circulation. Therefore, the input pipe supplying “cold” water (return) and the output, with heated water, should be located at different levels: the first at the base, and the second – in the upper part of the chamber where heat exchange (fuel, chimney, oven cap) occurs). When using the circulation pump and forced circulation, this may not be so important, but in this case, the maximum natural circulation must be provided for furnace boilers. Since in heating devices using solid fuel, which include stoves, almost never forced circulation is used in its pure form, but only together with natural, with the possibility of switching from one mode to another in the absence of electricity (using the bypass). And if there are conditions for normal circulation, the circulation pump is easier to create forced.

Now think about various furnace boiler or heat exchanger designs for a stove that has a water circuit. from various materials, with varying degrees of complexity, but which, with some metalworking expertise and welding proficiency, you can create yourself. In dire circumstances, you may opt for a compromise option: pick the best design, get the materials ready (sheet metal or pipes of the necessary diameters and thicknesses), and hand the welding work over to a skilled welder.

A feature of the heat exchanger for the heating furnace located in the fuel is that in its upper part it is usually closed by shelf of sheet metal or pipes. Since the maximum flame temperature in its upper part, thus, is achieved the most effective heat fence and the transfer of it to the coolant. Its design and dimensions should be such as to ensure the maximum efficiency of the water circuit, but at the same time not to prevent loading and normal fuel combustion.
Such furnace boilers can be made of sheet metal 4-5 mm thick, round pipes with a diameter of 32-57 mm, or rectangular pipes 30-40×50-60 mm. Best if the pipes used for this are seamless. Otherwise, the seam lines must be placed towards the brickwork and pre -boiled welding.

These heat exchangers can be arcuate (with arched brick overlap) or even (when overlapped with flat cast iron slabs), depending on the shape of the fuel overlap.

The following are potential solutions for a heating furnace where the fuel overlaps flatly:

Rice.1 A 4-5 mm thick sheet steel heat exchanger for a heinching stove.

Additionally, as seen in the image on the left, it is possible to combine sheet iron and pipes. Here, a row of circular pipes has taken the place of the upper solid shelf. In addition, depending on the furnace’s location and the layout of the water heating pipe wiring, the supply pipe in both the first and second "return" versions may be welded from the back or from the side (either one hand or both).

It is also an option to replace the side walls of such a heat exchanger with pipes that have a round or rectangular profile and can be positioned both horizontally and vertically.

This type of boiler made of pipes is feasible for a heating furnace with an arched fuel overlap:

The installation of a water circuit in a Russian furnace is also possible with this type of register. In this instance, the hob’s arch and the pipes’ bending curvature must match.

The characteristic that sets heat exchangers for kitchen plates or heating-welding furnaces apart is that, in order to access the flame on the hob, their upper surface must be fully or partially open. Such furnace boilers can also have pipes or sheet steel ("book") on their lateral surfaces.

The heat exchanger’s heating and heating-welding pipe designs can be the same if it is situated outside of the fuel. In this case, the dimensions of the cap—or, in the event that flue channels are not present, the type, design, and size of the space where heat exchange registers will be installed—are more crucial.

Such structures can be made out of sheet iron and pipes for heating-welding furnaces or kitchen slabs (see photo or rice. 2 below).

Additionally, the choice is only available from the pipes with rectangular and round profiles (rice.3).

Rice. 3 Pipe register options: 1- 40 x 60 x 4 mm rectangular pipe; 2- 40 or 50 mm round seamless pipes with 4-5 mm wall thickness; Round pipes with a diameter of 32 or 40 mm are number three; a 50 mm pipe that supplies heated water to a water heating system is number four; a 50 mm "return" pipe is number five; and a B, C, and D are the dimensions that are determined based on the boiler’s required power (see below) and are also accepted based on the fuel and furnace door sizes.

As seen in the image on the left, there is also an additional choice available from the pipes of the round cross section for the kitchen slab or the heating-welding stove, in the shape of two horizontal circuits joined by vertical tubes.

It is also feasible to use this type of heat exchanger (boiler, register) made of round pipes for a stove or heating and welding stove:

Furnace boilers are typically installed in kitchen plates, heating-welding furnaces, or fuel for heating. If there is essentially none in the case of the alternative kitchen plate, then the furnaces may be located in a different and, some experts believe, more effective location—outside the fuel. Due to the fact that the conventional configuration of the fuel’s heat exchanger causes the water circulating within it to drop in temperature, which exacerbates the fuel’s combustion conditions and increases the amount of soot produced as well as the furnace’s efficiency.

Additionally, the heat exchanger circuit’s water has the greatest impact when it flows in the direction of the heat flow, meaning that its colder portion should come into contact with stove gases that are colder and its hotter part with hotter. The heat exchanger’s corrosion is lessened in this instance because there is less condensate on its surface. It is challenging to guarantee such conditions when putting a furnace boiler in the fuel.

The solution may be the location of the heat exchanger in the cap of the furnace or its vertical chimney (depending on the structure). From this point of view, a cap of chimney looks especially attractive. Hot gases linger in it up to cooling the furnace. Inside it, you can simply place a large -volume heat exchanger and the area of contact with hot gases, welded from pipes, and its different structures are possible. Hot gases in the cap first rise up, and then go down to the exit to the chimney, giving their thermal energy to the boiler on the way. In the same way, you can think over the placement of the register in vertical chimney with the movement of flue gases down. But at the same time it is necessary to take into account that their cross section should be sufficient to ensure good traction.

However, the location option must be chosen in each case based on the kind of furnace, its shape and structure, and the kind and model of the most common heat exchanger.

The power of the heat exchanger of the water circuit of the furnace, which is necessary for heating the premises of the house depends on their area (volume) and the degree of insulation of the enclosing structures: the walls themselves, ceilings, windows and doors. As an average indicator, you can focus on 1-1.2 kW for every 10 m 2 at a ceiling height of 2.5-2.7 m. That is, for a house with an area of 100 m 2, on average, you may need a furnace boiler with a heat capacity of 10-12 kW.
The power of the heat exchanger itself depends on the area of the surface of contact with the hot medium (fire or hot gas). On average, it is believed that its specific thermal power is from 5 to 10 kW with 1 m 2 of the contact area of ​​such a boiler, depending on the temperature of the hot gases washing it and the temperature of the water at its entrance and output, which largely depend on the type of fuel and regime Topies. To find out the full power, it is necessary to multiply the useful area of ​​the heat exchanger by specific power:

The specific power can be computed using the following formula:

The heat transfer coefficient from the heating medium to the coolant through the steel surface is expressed as K = 12 kcal/h at 1 Ξ \.

Tm is the heating environment’s average temperature (max. + min. / 2) in degrees Celsius;

Tm: The coolant’s average temperature (incoming + output / 2) in degrees Celsius in the register.

For instance, if the stove runs continuously on coal, then:

800 o C is equal to 1000 + 600 /2.

Qu is equal to 12 (800-70) kcal/h, or 10.2 kW.

If the stove runs for a couple of hours at a time, the hot medium temperature will drop (maximum: 700 and 300, respectively), and we will get the following results at the same coolant temperature:

Qu is the maximum that can be obtained from 1 m 2 of its surface, or 12 (500-70) = 5160 kcal/hour or 6 kW.

Register area is calculated depending on its type. If it is made of sheet metal, then the total area is calculated, which is in contact with the hot environment. In the case of using the heat exchanger from round pipes, their diameter (in m) is multiplied by 3.14 and the total length of the pipes in contact with hot gases. If the pipes are rectangular, the perimeter of their cross section is taken and is also multiplied by their length. If the boiler is combined, consists of different pipes and sheet metal, then their area is calculated separately, and then summarized.
If the total required power of the heat exchanger, the type of fuel and the furnace mode (and therefore specific power) are known, then you can easily determine the required useful area of the future boiler and its dimensions, depending on which materials it will be made (pipes or sheet steel ):

The heat exchanger for a stove or boiler can also be made with your own hands from the sections of cast -iron radiators, even used. If sections of the old radiator are used for this, then before assembling them it is necessary to rinse from the inside with a weak solution of hydrochloric acid (6-7%), and then with pure warm water to cleanse their inner surface from all deposits. In addition, using a special key, it is necessary to disassemble the radiator to the section (even new) and replace rubber or cardboard gaskets between them with asbestos threads impregnated with graphite lubricant. After that, having calculated the required number of sections for the heat exchanger (each area is about 0.25 m2), they are connected to one structure.

A register of this type may have one or two rows of sections. As with installing cast-iron radiators, the heating system pipes are connected to this design using threaded connections and the appropriate adapters, corners, and drives. However, asbestos threads—rather than pakals—must be used to compact threaded joints that will be subjected to high temperatures.

Such a heat exchanger must be checked for tightness after it is manufactured, even before it is installed in the furnace. To do this, water must be poured into the heat exchanger to ensure there are no leaks. Since this type of heat exchanger will be fairly large, it is preferable to install the ego in a chimney or other chimney rather than in the fuel. Furthermore, cast iron is susceptible to cracking when it is exposed to sudden changes in temperature, such as from one side of a flame to the other—cold water.

DIY heat stoves for stoves with a water circuit

The stove needs a heat exchanger installed in it that circulates a liquid coolant, usually water, in order to be used as a heat source for a water heating system. It goes by the names stove boiler and register as well. This post will discuss how to construct a DIY heat exchanger for a furnace and how feasible it may be, based on the kind of furnace and the materials utilized in construction.

What can be made of furnace heat exchanger

Using steel pipes (round or profiled) with the same wall thickness and a diameter of 30–50 mm, or leaf steel (3-5 mm thick), you can create a DIY heat exchanger for the furnace. An alternative for this application could be a copper or stainless steel pipe or sheet. However, because of their high cost, these materials are hardly ever used in the independent furnace boiler manufacturing process.

From sheet metal, such registers are easier to make. They are easier to clean during operation. But, as a rule, they have a smaller area of contact with flame or hot gases, since for the most part they are continuous and only their internal surface faces the flame participates in heat exchange.
stove boilers from pipes, with the same overall sizes, as a rule, have a large heat exchanger area (although it also depends on the amount and on the diameter of the pipes), since they allow flame or to contact hot gases, practically, from all of them surface. But they are more complicated in the manufacture. This is especially true for structures consisting of completely round cross -sectional pipes.

It is ideal if seamless (whole) pipes are used in the construction of a heat exchanger for a stove with a water circuit. If suture pipes are used, the seams on the outside of the register (from the side of the brickwork) will need to be further reinforced with a weld.

Pipes and sheet iron combine frequently in the stove boiler manufacturing process. This is done to take advantage of their advantages, which include making it simpler to make and having a sufficient heat exchange area.

What species can do homemade furnace heat exchangers

In addition to the structural variations mentioned above, the design of furnace boilers can also vary based on the kind of furnace for which they are meant to be used, as well as the material chosen for their manufacture. These stoves can be heated or heated and fused.

The upper portion of the heat exchanger’s design for the heating and welding furnace is distinguished by an open area that allows the flame to reach the hob. The upper portion of heating furnace registers is typically sealed with a continuous sheet of pipes or rows of them.

The dimensions and form of the furnace boilers are chosen based on the required thermal power as well as the size and shape of the area in which they are intended to be installed—typically, the furnace fuel.

Boilers for heating furnaces with a water circuit

Here, we will look at the three most popular designs that are created using pipes and sheet metal separately and in combination.

The heat exchanger is a continuous, P-shaped structure made of sheet metal that is intended to be placed inside the heating furnace’s fuel. The interior walls serve as the heat exchange surface.

Heat-metal heat exchanger used in furnace heating

Cutter. The system’s cold water is fed via the "return" into the lower U-shaped pipe of the heat exchanger’s base (which has a diameter of 40–50 mm and a wall thickness of 3–4 mm). The lower U-shaped pipe then rises and enters the upper pipe-collector, where it enters the house’s heating system, already heated, according to Mr. U-shaped base or less. Although this type of register is more efficient than one made of sheet steel, it is also more challenging to produce because numerous pipe joints must be made and then welded.

Stove register made of pipes for a heating furnace

This register’s lateral surfaces are continuous panels with a thickness of 40–45 mm, formed of sheet metal that is 3–5 mm thick. A series of horizontal pipes with a diameter of 40–50 mm connect the panels at the top.

If you choose to manufacture it yourself, it is important to note that using pipes rather than a continuous surface (as in option 1) increases the area of contact with the heating medium. Additionally, using leaf metal for the side panels simplifies the manufacturing process.

Sheet metal board and furnace heating pipes

Boilers (registers) for heating and welding furnaces

Sheet iron and pipes (round or profiled) can also be used as heating exchanges for heating and welding furnaces, as well as when combined. Think about a few choices.

Heat exchanger for a kitchen slab or heating-welding furnace, shaped like two continuous sheet metal side panels joined together like a "book."

Furnace heat exchanger for the heating and welding system

The chimney of round and rectangular pipes: round (with a diameter of 40-50×4 mm) are located horizontally and connected to the structure using rectangular 50-60x40x4 mm. Such a combination of different types of pipes facilitates the manufacture of the boiler. Dimensions a B C And G are calculated, depending on the size of the fuel and the required power of the register power.

Heat exchanger made of round and profile pipes for use in welding and heating furnaces

Heat-expanded register limited to pipes that are round. Two horizontal contours are joined by vertical pipes to form this shape. The lower circuit receives cold water from the system, while the upper circuit receives heated water that is then returned to the heating system.

Sign up for the furnace that heats and welds pipes.

The effectiveness and efficiency of your heating system can be greatly increased by adding a heat exchanger to your brick furnace. These devices help to maximize the energy output of your furnace, which ultimately results in lower heating costs and a smaller environmental impact. They do this by capturing and utilizing waste heat that would otherwise be lost.

The capacity of a heat exchanger to return heat from combustion exhaust gases to the incoming air or water is one of its main benefits. This procedure guarantees that more of the energy produced is used for heating your home rather than being wasted, in addition to improving the furnace’s overall efficiency.

Furthermore, by lowering the quantity of pollutants and particulate matter released into the atmosphere, heat exchangers can help to improve indoor air quality. They contribute to making your home and your family’s environment cleaner and healthier by absorbing and containing these dangerous emissions.

By lessening the strain on your furnace’s components, installing a heat exchanger can also increase its lifespan. Your furnace is likely to require fewer repairs and maintenance over time if it operates more efficiently and experiences less stress while in use, ultimately saving you time and money.

In conclusion, anyone wishing to maximize the efficiency of their brick furnace would be wise to invest in a heat exchanger. It can help extend the life of your heating system and improve efficiency while lowering heating costs and contributing to a cleaner environment. Considering these advantages, installing a heat exchanger is unquestionably worth the cost.