How to make a solid fuel boiler of long burning with your own hands: drawings and assembly instructions

Do you want to replace the heating system in your house? You’re on the right track for economical and effective heating if you’re thinking about installing a solid fuel boiler. Although it may seem difficult, building your own long-burning solid fuel boiler can be a rewarding do-it-yourself project if you have the right advice and instructions. This post will explain how to build a solid fuel boiler from the ground up that is both long-lasting and effective. It will include comprehensive assembly instructions and drawings.

There are benefits to using solid fuel for home heating. In addition to being frequently less expensive than alternative heating techniques, it also offers a dependable source of warmth, particularly in places with restricted access to other fuel sources. Furthermore, when biomass or wood pellets are used as sustainable fuel sources, solid fuel boilers can be green. You can take charge of your heating system and lessen your carbon footprint by building your own long-burning solid fuel boiler.

Understanding the fundamentals of a solid fuel boiler’s operation is crucial before beginning construction. In order to produce heat, a solid fuel boiler essentially burns solid fuels like coal, wood, or biomass. After that, the heat is converted to water, which is then circulated through the boiler and heated radiators or underfloor heating systems throughout the house. The boiler’s construction and design, which provide ideal combustion and heat transfer, are crucial to obtaining long-burning efficiency.

Careful planning and meticulous attention to detail are necessary when building your own solid fuel boiler. Thankfully, there are lots of tools available to help you along the way. With comprehensive drawings explaining the boiler’s construction and easy-to-follow assembly instructions, you will have all the knowledge you need to confidently take on this do-it-yourself project. Building a solid fuel boiler can be a gratifying and rewarding project, regardless of your level of experience with do-it-yourself projects or desire to learn new skills.

Materials Needed	Step-by-Step Instructions
Steel Barrel or Cylinder	1. Obtain a steel barrel or cylinder of appropriate size to serve as the main body of the boiler.
Insulation Material	2. Acquire insulation material such as fire bricks or rockwool to line the inside of the barrel.
Grate	3. Create or purchase a grate to hold the fuel inside the boiler.
Chimney Pipe	4. Procure a chimney pipe to allow for the escape of smoke and gases.
Fire Door	5. Design and install a fire door mechanism to control airflow and fuel feeding.
Ash Pan	6. Fabricate or find an ash pan to collect the ash from burnt fuel.
Assembly	7. Cut an opening in the barrel for the fire door and chimney pipe.
Insulation Installation	8. Line the inside of the barrel with insulation material, ensuring full coverage.
Grate Placement	9. Install the grate at the bottom of the barrel to support the fuel.
Chimney Attachment	10. Connect the chimney pipe securely to the opening at the top of the barrel.
Fire Door Installation	11. Mount the fire door mechanism over its designated opening, allowing for proper ventilation control.
Ash Pan Setup	12. Place the ash pan beneath the grate to catch ash and debris.
Testing	13. Before use, test the boiler to ensure proper ventilation and combustion.

The principle of operation of a long burning boiler

One bookmark will burn for six to seven hours in an average solid fuel unit. As a result, the room’s temperature will drop right away if the next batch of resources is not added to the furnace. This is because the room’s primary heat source circulates based on the free gas movement principle. Warm air rises from the flame and moves outside.

One fireplace can provide enough heat for one to two days using the long-burning boiler. Some models have a seven-day heat retention period.

Why is it that such efficacy and efficiency are attained?

The boiler’s operating plan

Two combustion chambers operating simultaneously distinguish TT boilers with prolonged burning from conventional boilers. In the first, the fuel burns normally, and in the second, simultaneous gas releases occur.

The timely supply of oxygen, which the fan provides, is crucial to this process.

This idea has only lately been put into practice. This technology was first introduced by the Lithuanian company Stropuva in 2000, and it quickly gained popularity and rhinestones.

Long-burning homemade boiler

Currently, this is the most affordable and useful method for heating a rural home in cases where gasification is unavailable and power outages happen.

These devices operate by burning fuel at the top. The firebox, which is normally positioned below in all furnaces, enables you to raise and heat cold air from the floor.

This boiler operates on the basis of a trip to the pyrolysis. The primary source of heat released in this instance is not the combustion of solid fuel, but rather the gases that are released during the process.

The actual combustion process takes place in a closed environment. The released gas enters the second chamber through the telescopic pipe, where it completely burns and mixes with cold air to power the fan.

Long-burning TT boiler (scheme)

This procedure keeps going until all of the fuel has been consumed. With this kind of combustion, a very high temperature—roughly 1200 degrees—is reached.

The main large and small cameras are installed in this boiler, as was previously mentioned. The actual fuel is placed in a sizable chamber. It has a 500 cubic meter maximum volume. Dm.

Any solid fuel, such as sawdust, coals, firewood, or pallets, can be used as a resource for combustion.

A built-in fan maintains a steady flow of air. This method’s advantage is its extremely slow consumption of solid fuel.

This considerably raises the heating device’s efficiency. When compared to a regular stove, why does firewood burn so slowly?

In the end, because the air is pushed out from above, only the top layer burns out. Additionally, the fan only adds air once the top layer has burned through entirely.

Many models that operate on the same principle are currently available on the market, however their efficiency varies based on factors such as dimensions, execution material, and extra options.

Because they can run on any fuel, Universal TT boilers will operate much more simply. A long-burning wood boiler is a less expensive option. It can only run on wood; it cannot run on any other fuel source.

A feature of the design

Any boiler that burns for an extended period of time has an enormous chamber where fuel is placed. The length of time the firewood will burn out increases with the size of the boiler installed in the camera.

Two technologies that are currently used in TT long-burning boilers effectively compete with one another. This is the sling technique and the Bulerian principle.

In Russia, this method is not as common because of the high cost of the sling and its intricate design. However, the Bulerian method states that people’s craftsmen build country homes and cottages with a great deal of dedication when creating heating units.

The boiler method consists of a metal case with two cameras inside of it. Fuel burns in the lower chamber, and a gas that enters the pipe from the first chamber burns in the second chamber.

Since the entire lower portion of the boiler housing is reserved for a substantial resource laying, the fuel loading door is located in the upper portion of the housing.

A smoke pipe that leads to the chimney is located at the top of the boiler. The lower section houses the ash chamber, which is used to clean the boiler.

One more detail that needs to be brought up. The ash in a typical furnace serves as a blower, allowing the air needed for combustion to pass through it. Since air enters the upper air chamber and functions as a recuperator in this instance, the ash chamber is completely sealed.

The damper at the top of the air chamber controls the amount of oxygen that the boiler receives. The distributor is lowered and the fuel gradually settles as the firewood burns. This ensures a steady flow of oxygen.

Simply pull up with a fresh fuel load and go back to distributing to his starting point. You can quickly ascertain how much fuel is left in the boiler and when to run the next load by looking at the position of this lever.

It’s important to discuss this heating option’s environmental friendliness separately. Carbon dioxide is almost completely burned, leaving no gas or fuel left in the atmosphere.

The TT boiler’s primary components allowed for prolonged combustion.

Basic components of the TT boiler:

1. Top chamber. This is the main element of any boiler and furnace, where there is a direct burning of fuel.
2. GAZ combustion chamber. Hot gases come here from smoldering firewood.
3. Ash – ash gathers here. This node must be systematically cleaned to maintain a boiler in a technically good condition.
4. Chimney – a knot through which combustion products are displayed.

A steel case, consisting of 5–6 mm thick sheet metal, encloses each of these nodes.

Advantages and disadvantages

A large cottage would make sense to heat with such a unit due to its large dimensions and intricate design. However, this option is not appropriate for a small summer cottage because it will not justify efficiency.

pros

• high efficiency (about 95%);
• autonomy of the heating system;
• economy;
• reliability and durability;
• high efficiency;
• fuel availability;
• environmentally friendly option for heating a house;
• Fuel versatility (coals, firewood, sawdust, piglets).

Minuses

• Combination of the structure;
• A special room must be equipped under the device;
• complexity of design and installation;
• need for constant cleaning.

Considering that a long-burning boiler is far more expensive than a typical furnace, purchasing one in its completed state is not required. If you know how to build and repair things at least a little, you can make this design on your own.

Appearance of a building constructed at home

When compared to the factory analog, the homemade structure has several advantages:

• low cost;
• the ability to make the boiler universal for any type of fuel;
• the possibility of improving the structure and adding power.

The boiler’s cylindrical shape is the only challenge. Giving a metal this shape with a metal is very difficult without a roller machine.

However, a good fix exists. You can use any pipe with a suitable diameter or empty scan cylinders. selected pipes with walls that are at least 5 mm thick.

You can fold a small brick furnace and enjoy its effectiveness for a village and a small summer cottage. However, since a large stock of firewood will be needed for the winter, this option will not be as practical for a large cottage. Maintaining a conventional stove is far more difficult than maintaining a long-burning boiler, and high temperatures in rooms far from the furnace make it impossible to set up a cozy microclimate in the home.

It would be far more reasonable in this case to build a solid fuel boiler yourself and not worry about its preservation or appearance if you lack the funds to build a complete heating system for your house or if the construction of such a system is inappropriate.

Useful tips for the manufacture of TT boiler

• If you want to make a TT boiler universal from the perspective of the use of raw materials, then for a furnace chamber use a pipe from heat -resistant alloy steel.

For the boiler, alloy steel pipe

Cord made of asbestos

Any solid fuel can be used with the circuit we attach below to operate the TT boiler:

• stone and brown coal;
• anthracite;
• firewood;
• wood pellets;
• briquettes;
• sawdust;
• Slants with peat.

Regarding the fuel quality, there are no particular guidelines at all. However, bear in mind that the boiler will not provide a significant useful action coefficient when the fuel humidity is high.

In this comprehensive guide, we"ll delve into the process of crafting a long-burning solid fuel boiler from scratch, right in the comfort of your own home. With detailed drawings and step-by-step assembly instructions, we"ll show you how to harness the power of solid fuels efficiently and sustainably. From selecting the right materials to understanding the combustion process, we"ll cover everything you need to know to create a reliable heating solution for your house. Whether you"re a seasoned DIY enthusiast or just starting out, this article will empower you to take control of your heating needs while reducing your environmental footprint. Let"s dive in and discover the art of building a solid fuel boiler that will keep your home warm for years to come.

Security measures!

Consider the primary aspects of fire safety to ensure that a boiler of this kind is truly a cost-effective and efficient heating option, has a long lifespan, and has not resulted in burns or accidents within the home.

1. It is necessary to monitor the temperature in the system and prevent it from overheating.
2. You can not install a shut -off valve on the pipeline.
3. Near the boiler you can not hold easily igniting objects.
4. It is necessary to monitor the ventilation in the room.
5. For the boiler you need to equip a separate room.

While doing the preliminary work, consider the location of the boiler installation.

Of course, it is ideal to outfit a separate boiler room because the way the TT boiler operates on prolonged burning differs slightly from how a typical brick furnace operates on firewood. Additionally, this unit’s exterior design won’t catch the eye or be used as a house decoration.

Although solid fuel still produces some dirt, it is best to install TT long-burning boilers in non-residential spaces.

However, if its power is modest (beyond 30 to 35 kW), you can easily use a brick wall to zone the main room and the "boiler room."

Make sure the room where this boiler will be located has a ventilation system. Continuous supply of oxygen should come from the streets.

Step -by -step instructions for creating a solid fuel boiler for long burning with your own hands

The installation of a solid fuel boiler is a difficult undertaking that will not be simple to complete. Prepare drawings and sketches prior to beginning construction.

An illustration of a DIY solid fuel boiler

Additionally, get ready the following tools:

1. Welding machine.
2. Tools for working with metal: pliers, grinding circle.
3. Electric drill.
4. Building level and roulette.
5. Marker.
6. Bulgarian.
7. Gloves and protective screen on the eyes.

Take note! You should use extreme caution and at least some basic welding machine experience when working on the construction of a homemade TT boiler with prolonged burning. Wear safety gear whenever you work with welding.

Of the supplies that are required:

1. Empty gas cylinder.
2. Sheet metal.
3. Asbestos cord.
4. Steel pipe with a section of 60 mm.
5. Metal loops and pens.
6. Metal corner or blades.
7. Metal hood.
8. Basalt fiber for passage of a chimney pipe.

We advise you to familiarize yourself with the video instructions on how to properly cut an empty gas cylinder before beginning manufacturing. Pay close attention and don’t overlook security precautions!

Step 1. Building and making the case

Mark the propane cylinder with the marker in accordance with the drawing’s size.

We drill a tiny, rectangular hole beneath the ash door so that the boiler can be cleaned through it.

To cut the top, we draw a flat line around the entire circumference of the upper part of the cylinder.

Cut off the top with a grinder along the line.

Slice off the cylinder’s top.

We are now marking the hole in the middle where the pipe will pass. The diameter of the pipe should not match the hole, respectively.

To ensure that the pipe inserted into the cylinder is securely clamped, cut a hole in the lid and weld the metal ring.

Circular welds of the ring

The cylinder’s exterior and interior are scoured with a thin band of sheet metal (4-5 mm), which will eventually be covered by the lid.

Step 2. Pipe manufacturing

We take an 80–100 cm long metal pipe. Consider that the pipe height needs to be 20–25 cm higher if you cook the boiler’s body yourself rather than using a standard propane cylinder. The fundamental idea behind the work is that the pipe inside the case will collapse as the fuel runs out.

We weld a metal air distributor circle to the pipe’s lower section.

Slice off the cylinder’s top.

After laying the asbestos cord, we cut out of the mount’s sheet metal, which we then consistently weld along the cylinder cut’s line.

Handles should be welded to the lid.

We attach the cut off in a way that makes it simple to take off and put back on. Construct a handle out of metal and weld it to the body for ease of removal.

Step 3. Making a pipe to a chimney

Mark the cylinder’s upper section where the pipe hole is located.

To remove combustion products, cut the pipe with a grinder and weld it.

This pipe is then joined by a steel chimney pipe.

Step 4. Making ash

We used a grinder to remove the hole in accordance with the marking that was previously made beneath the ash chamber.

We construct a door separately out of sheet metal, and it will subsequently need to be screwed to the boiler housing brackets.

A hole

You can attach a handle to a small loop of thick wire or reinforcing rod for convenience.

Step 5. Preparing the air supply system

Calculate the cylinder body’s internal diameter. Now, on a sheet of metal, draw a circle whose diameter is 5 mm less than the cylinder’s interior diameter.

This circle should be cut with a grinder.

This is the appearance of the air supply system.

We cut a metal corner into six equal pieces. Every component measures ½ of the metal circle’s diameter. The impeller with the old blades is still functional for these purposes.

We create a system for supplying air.

Weld metal circles counterclockwise in the same direction.

Step 6. We make a heat exchanger

We are going to construct a heat exchanger based on the water circuit principle.

The heat exchanger’s size is customizable to suit your individual needs. More firewood can be placed inside of it as it gets bigger, which will result in a longer burning time for your boiler.

Cut out the sheets of 5–6 mm thick sheet metal in accordance with the design, then weld them into a sturdy case that will house our gas cylinder.

Nozzles are used in the top and bottom sections of the case to join the feed and return lines.

There needs to be a hole made in the middle for the fuel to be placed through. We cut out a grinder and mark the area with a marker.

Step 7. General assembly and installation of the boiler

We secure the furnace’s ash door.

We use a grinder to remove the ash and mark the location on the heat exchanger housing. We also install a door in this opening, and it should shut tightly to prevent the body from receiving oxygen.

The cylinder is placed inside the heat exchanger.

Weld the tank on top with the aid of a welding machine to create a completely sealed case that houses a circular firebox.

The oxygen supply system’s function of limiting the air supply from above is the fundamental component of the TT boiler’s prolonged combustion.

The fuel (briquettes, coal, or firewood) should be packed tightly to minimize the amount of space between the layers. If the firewood varies in size and cannot be fitted tightly, you can place a chip or piece of paper in between the layers. The firewood will burn for a longer time if the solid fuel mixture is denser.

Boiler load density should be high.

How is such a boiler going to be loaded?

• we take out the air supply limiter from the body;
• We load fuel through a special door. The fuel is preliminarily sprinkled with a special ignition liquid;
• Put the limiter pipe back;
• We throw a lit match inside the boiler;
• After making sure that the fuel gradually begins to smolder, tightly cover the door.

The pipe inside the cylinder will gradually sink as the firewood burns. You can always tell how much firewood is inside by looking at its height.

Step 8. Prompting the boiler

During the warm season, you can perform such a basic boiler right on the street and test it outside, giving it a makeshift chimney.

If the room is larger than thirty to forty square meters, you can cook two cylinders vertically, which will increase the amount of firewood that is laid.

Step 9. Installation of the boiler in the room

Pay close attention to the boiler’s fire safety.

To prevent burns, it is preferable to designate a small fence separating it from the residents or to highlight a separate room. However, the boiler’s body is made of metal, so there’s a greater chance of getting burned than in a stone furnace.

Install in the location where the chimney’s conclusions may be possible. There are two ways to remove a chimney: through the wall or through the roof.

Remember that nothing should be placed 50 centimeters away from the boiler because you should have direct access to it.

• Perform the base of brick under the boiler, laying a continuous brick in 2 rows. Check the construction level with the construction level.
• Observe the distance from the walls (regulated by SNIP). From the furnace door to the wall, the distance should be at least 125 cm. The distance between the side parts and the back of the boiler and the wall should be at least 700 mm.
• If the walls in the house are made of wood or any other combustible material, it is necessary to protect the boiler adjustment place with sheet metal or basalt. You can use the usual brick as thermal insulation, which should be overlaid along the perimeter of the boiler adjustment place to the wall.

It’s also important to make sure there is enough thermal insulation where the chimney exits through the wall or roof. Basalt fiber works well for this and should be layered firmly between the overlap and the chimney pipe.

• Install the boiler on the prepared foundation and again check the level of how exactly the device is worth. Keep in mind that the gas output pipe should be at the same level with the chimney pipe. If the line is not horizontal, then the thrust during operation may be broken.

Step 10. We connect the boiler to the chimney.

Take note! It is essential to use sealant to lubricate the joints between each component of the chimney. The chimney pipe is connected to the boiler’s TT pipe. The diameter of the chimney and the boiler’s TT pipe must match. These settings won’t be taken into consideration if the bandwidth is not maintained.

Attachment to the chimney

As you can see, everything that appears difficult at first glance can actually be accomplished quite well by doing everything by hand! If you carefully follow the directions, you will soon see that a solid fuel boiler with a long burning time has much higher performance and efficiency than any of its competitors that use an open flame. This will require little maintenance to keep the house’s microclimate comfortable.

For homeowners wishing to improve their heating systems, building your own long-burning solid fuel boiler is not only an affordable solution, but also a satisfying do-it-yourself project. You can build a dependable heating source that will effectively keep your house warm by adhering to the meticulously designed drawings and assembly instructions.

Building your own solid fuel boiler has many benefits, one of which is that you can tailor it to your own requirements and tastes. It is possible to modify the design to suit your needs, regardless of whether you have restricted space or particular fuel requirements. With more control over your heating system thanks to this flexibility, comfort and performance are guaranteed.

Furthermore, building a solid fuel boiler from the ground up can be a rewarding experience that gives homeowners authority over their heating requirements. Every stage of the process, from obtaining supplies to putting the parts together, offers a chance to pick up new skills and hone existing ones. The satisfaction of witnessing the completed product in action—that is, effectively heating your home—is incomparable.

Additionally, you can lessen your impact on the environment by building your own long-burning solid fuel boiler. Reducing dependence on fossil fuels and promoting sustainability are two benefits of using renewable fuel sources like biomass briquettes or wood pellets. Furthermore, a well-designed boiler can reduce emissions through the efficient combustion of solid fuels, making it a cleaner heating option.

In conclusion, building a long-burning solid fuel boiler yourself has many advantages, including lower costs, greater customization, and environmental sustainability. With clear assembly instructions and comprehensive drawings, homeowners can confidently take on this do-it-yourself project and create a dependable heating solution that meets their needs. So why not get your hands dirty and begin constructing your own solid fuel boiler right now?

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