Archive for January, 2009

There is a limit…

Friday, January 16th, 2009

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Last night the weatherman on television was delighted to be able to report that we would see low temperatures like we haven’t seen for years.  In some ways, this was good news to me; I’d get to see how the little boiler would do in our big, old house in very cold weather.  Not wanting to risk any frozen pipes, I adjusted the AquaStat on the oil boiler to kick in if the water in the system dropped below 150F.

Today's temp

Today's temp

At 6:00 a.m. today, my thermometer said -30F.  The house was at the temperatures we customarily keep, and the kitchen was cool, as it generally is during hard cold snaps.  There is insufficient fin tube in the kitchen to heat it effectively in very cold weather and it faces northwest.

I heard the oil burner kick on and run for about five minutes indicating that water temperatures in the system had dropped below 150F.  When I go up, I checked the systems, and the MESys 4000 had a boiler temperature of 172F despite the fact that all five zones in the house were calling.

Showers, morning dishwashing, and keeping up with the house dropped the water temperature below 150F once more giving the oil burner another four or five minutes of catch up.  For the balance of the day, no oil burner time was required, and the house stayed at its usual temperatures.

I gained confidence that the little boiler would have kept the house from freezing on those conditions, but layered clothing would also have been a good idea.

Dutch Dresser

Ash cleaning intervals/MESys boilers

Thursday, January 15th, 2009

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Until you begin to understand all the variables associated with ash cleaning intervals in a pellet fired boiler system, the question, “how often do you have to remove the ashes?” seems simple enough.

I decided to test my MESys 4000 boiler to point of failure by not removing ash until a “Problem! Low chimney draft” error indicated it was shut down due to the problems of ash build-up.  Through a couple of test cycles, it became clear that around .8 tons (1600 pounds) of the pellets I’m using would create enough ash to fill the boiler enough to shut it down.  By test, we know that those pellets contain 1% inorganic ash; so, my system can handle 16 pounds of ash before a cleaning out is required.

My boiler is purposefully undersized for my house, yet it has managed to carry the house’s heat and domestic hot water demands even into this week’s sub-zero weather.  This morning at -12F in my backyard, boiler water temperature was at 177F when I checked it at 6:00 a.m.  To provide this heat for the house, I am burning approximately 100 pounds of pellets per day.  That means that I should plan to clean the ashes out of the boiler every two weeks during this weather in which the burner is running at maximum output full time.  (I clean it every other Sunday; it takes a half hour.)

The MESys 6000 boilers are using roughly 120 pounds of pellets per day when they are in full fire conditions.  They will handle 40 pounds of ash or more between cleanings.  That means that regular cleanings for those boilers should be scheduled approximately every 30 days if they’re operating under full fire conditions using pellets that generate 1% ash.

The last qualifier is important.  Pellet ash content varies among manufacturers and even among mill runs.  Pellets produced and tested to PFI (Pellet Fuels Institute) standards that are labeled “premium” will contain inorganic material to produce 1% ash, or less.  It’s not uncommon for pellets to have 0.5% ash, which would double the cleaning intervals.

Some of our boilers are in the Arctic Northwest, and the pellets there are so clean that ashscrape cycles are set to the available  maximum setting of a scrape every 144 pounds and, even then, the scraping is unnecessary, and ash content of the pellets is at, or below, 0.3%.

Dutch Dresser

A pellet’s a pellet, right? Well, sort of!

Friday, January 9th, 2009

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In the interest of disclosure, I am a Director of Maine Energy Systems.

Wood pellets

Wood pellets

Burning pellets for home heating is a wonderful way to reduce one’s carbon footprint.  Wood pellet fuel is considered by scientists to be a carbon neutral fuel because the carbon released during combustion is in the active carbon cycle.  Trees gather carbon from the atmosphere and release it when they decompose or are burned.  In fairness, the fossil fuel used in the production and transportation of wood pellets makes them closer to 70% carbon neutral when their full life cycle is considered.

Burning pellets requires that appropriate quality pellets be used for the burning appliance.  Sophisticated boilers should burn premium quality pellets, while mills can use much “dirtier” industrial pellets. There are many measurable attributes of pellets, and they have all been carefully measured by the Europeans for years as they’ve burned pellets in increasingly sophisticated appliances.

As we deliver pellets in our bulk delivery trucks and burn them in our Bosch/MESys systems with their Janfire NH burners, we learn more and more about how important the various attributes of pellets are.  Let’s talk about a few simple ones.

Moisture content: Under the standards proposed by the Pellet Fuels Institute, a voluntary manufacturers’ organization, moisture content for premium pellets must be equal to, or less than, 8%.  The Swedish burner manufacturers with whom I’ve talked think that we’re a bit wasteful drying the fuel that much.  Most European standards call for 10-12% moisture in premium pellets.

Heating value: Measured in BTUs/pound this value is presented various ways:  as received, moisture free, and moisture & ash free. As received values will commonly range between 7,500 BTU/lb and 9,000 BTU/lb. Generally, the higher the proportion of softwood in the pellets, the higher the heat value, an idea that’s counter-intuitive to cordwood burners.

Ash content: PFI proposed standards call for premium pellets to have 1%, or less, inorganic ash content.  This falls in the middle of European standards, which range from 0.5% to 1.5% ash content for premium grade pellets.  In practice, the home pellet burner will notice this attribute most.  The higher the ash content, the more frequently stoves or boilers will have to be cleaned.  MESys distributed pellets are under 1% ash, so boiler owners can expect to remove about 20 pounds of ash for every ton of pellets burned.  A MESys 6000 can easily hold 40 to 60 pounds of clean ash.

Pellet durability: As pellets are handled some break.  Since delivering and automatically feeding pellets to boilers systems requires machine handling of the pellets, it’s very important that pellets be durable.  Regional manufacturers are beginning to understand the importance of high durability pellets and are modifying their processes to make harder pellets.  European standards, and proposed PFI standards, call for pellets of 97% to 98% durability when shaken in a standard test unit.

All of these things are of interest to me as I work to make central heating with wood pellets convenient for American homeowners; they needn’t be of much concern to homeowners as long as they purchase their pellets from a trusted, reliable source offering truly premium grade pellets.  Janfire burners will be carefully configured at installation for the pellets being burned using net heat value and pellet density information to produce the most efficient combustion possible.

Dutch Dresser

First refueling with bulk pellet delivery

Thursday, January 8th, 2009

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In the interest of disclosure, I am a Director of Maine Energy Systems.

When my MESys 4000 (wood pellet fired boiler system) was installed and ready to run, we loaded 3,120 pounds of pellets carefully into the fabric bin in my basement.  My bin is designed to hold 3.2 tons of pellets, but I took what was left in a delivery truck when the day was over.

MESys large delivery truck

MESys large delivery truck

The boiler ran well producing heat and domestic hot water as it burned pellets at the rate of roughly 100 lbs/day in very cold weather.  When the burner indicated it had burned 0. 64 US tons of pellets (1,280 pounds), I removed the ash for the first time and marveled at how empty the storage bag looked. There were no pellets above the pyramid base.

I couldn’t help myself, I got out the tape measure and the old geometry book to try to determine the volume of the pyramid shaped base of the bag system.  The volume of the pyramid (6.6′ square by 3.3′ tall) proved to be 47.4 cubic feet, a volume that would hold nearly 1900 pounds of pellets. Sure enough, what was left and what had been consumed totaled what was initially loaded. It’s always fun when arithmetic works.

Fabric bin, 3.2 tons

Fabric bin, 3.2 tons

A couple of weeks later, Rodney brought the 20-ton delivery truck to my house, attached the hoses and added 5,500 pounds of pellets to those remaining in the bin.  The delivery took less than an hour and left me a bin mostly filled with pellets.  I shouldn’t need another delivery until spring is in the air.

Dutch Dresser

Pellet boiler ash removal

Thursday, January 8th, 2009

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In the interest of disclosure, I am a Director of Maine Energy Systems.

After burning 0.64 tons (1280 pounds) of Energex pellets according to the data made available by the Janfire NH burner on my system, I decided to remove the ash today to begin to get a baseline for proper ash removal intervals on my MESys 4000 system. The burner’s measurement is based on fuel density entered by the user; I entered 42.1 pounds/cubic foot based on weighing of several samples. An error in this setting would yield erroneous consumption figures.

In lab testing, the pellets I’m burning are reported to have 0.75% ash content, therefore, I was expecting approximately 9.6 pounds of ash. I opened the top and bottom doors of the boiler exposing the top of the cast iron core on the top separated from the lower chamber by removable baffles. After removing all the ash from the boiler, I weighed 12.6 pounds of ash, or nearly exactly 1% ash.

The bottom of the core was about half way up the bottom door with ash space below it. I found a small amount of ash on the cast iron and atop the baffles in the top section. I found a pile of clinkers below the burner resting on the inside bottom of the core, and I found talc-like ash in the bottom of the boiler enclosure. The clinkers were most interesting to me as they are the physical evidence of relatively low ash melting temperature (1250C) inherent in the pellets I am burning. We had been told of this attribute by the Swedish testing labs used by the burner manufacturers.

While the clinkers cause no issue for the burner or the system, they did keep some of the fine ash from falling to the storage area on the bottom of the boiler enclosure. Until regionally produced pellets have sufficiently high ash melting temperatures to resist the formation of
clinkers, I will open the top door and remove the clinkers every half ton, or so, to allow for reasonable ash storage in the base of the system. After burning nearly 1300 pounds of pellets, there was ample room in the base of the boiler for lots more ash in this four-section boiler. The ash from more than two tons would have easily fit in the storage bin at the 1% volume, I discovered in this ash removal.

The recommended ash removal interval for the six-section boiler is every three tons of fuel; I’d be perfectly comfortable allowing 2.5 tons of fuel to run through this four-section boiler before removing the ash. However, the whole cleaning process, including opening the boiler, cleaning, and closing the boiler took me only twenty minutes, so I’ll likely empty it more frequently just because it’s easy.

Dutch Dresser