Wood gasification process... Wood as a fuel... Boiler construction - its elements...4 Boiler construction - materials...4 EKO advantages...4 Boiler construction - schematics... Boiler dimensions... Boiler sizeing... ORLAN SUPER... Basic information about boiler assembly... Boiler interaction with a four-way mixing valve... Boiler interaction with operational water heater... Boiler connection scheme - examples...0 Additional equipment: Hydrometer... ORLAN SUPER additional equipment: Thermal safety device (cooling coil)... Additional equipment: LADDOMAT thermoregulator...
Wood gasification proces Gasification process in our central heating boiler is divided into 4 stages:. Drying and release of wood gases inside the loading chamber in slow glowing process.. Burning of gas mixture with secondary air in the lower chamber at 00 F.. Flame reheating and heat exchange. 4. Combustion gases ejecting through chimney flue after the boiler will reach desized oprational Wood as a fuel STAGE Wood drying and breakdown into gases tem-perature. The best indicator of successful wood gasification is the lack of smoke exiting the chimney. STAGE Burning of mixed wood gases with secondary air STAGE Releasing heat trough heat exchanger Wood is a renewable resource like solar, water, or wind power. They are all energy sources, which never become depleted, unless improperly managed. Wood is also a fuel, which may be stored and preserved without energy loss. Wood storing reduces its moisture and simultaneously increases its heating value (energy volume, which may be used up during burning process). STAGE 4 Ejecting combustion gases through smoke stack Modern boilers utilizing wood in gasification processes use energy contained in wood with efficiency that is three times higher than traditional boilers. Smoke and other emissions are cut to a very low level, making our boilers very nature friendly. ORLAN boilers are adapted for burning of any kind of wood ranging from sawdust to chunks of wood. The best way to achieve recommended wood humidity is to cut the timber during springtime, and let it seazon under a covering like a wood shed or a trap. Burning Zones DRYING ZONE CARBONIZATION ZONE OXIDATION ZONE REDUCTION ZONE STAGE 4 STAGE STAGE Best humidity for gasification should be in 0% range. Wood too dry (less than %) or too wet (more than %) will reduce boiler efficiency. STAGE Raw wood humidity ranges from 0% (wood cut in winter) to 0% (cut in summer). Most favorable wood humidity is obtained after - months of storing.
Boiler construction - its elements Sealed wood gasification chamber that is simultaneously used as a loading chamber. When appropriate amount of primary air supplied by the pressure fan is delivered, wood gas is generated A nozzle, made of refractory concrete, mixes wood gases with the secondary air and a flammable mixture is produced that undergoes self-ignition at about 000 F Exhaust reheat space - the main combustion chamber, where temperature reaches about 000 F serves as an ash pit A smoke tube heat exchanger (flue gas to water) heats up the installation water Afan that communicates with the microchip controller monitors the quality of the whole burning process Safe guard thermostat - each boiler is equipped with an additional safe guard thermostat, which switches off the fan while the water gets up to 0 F Steel turbulators in heat exchanger tubes. Boiler construction - materials Boiler body - boiler casing is made of welded metal sheets that are /4 inch thick, whereas the remaining walls are / inch thick. Heat exchanger - smoke tube heat exchanger made of tube with dimensions / inch x x/ inch Insulation - boiler thermal insulation is composed of glass wool of Nobasil /4 inch thick, while the external casing consists of metal sheet panels 0.mm thick (powder painted) Nozzle - ceramic element made of refractory concrete (working temp. up to 00 F) Chimney flap - made of high quality steel. Tight flap adhesion to the combustion duct assures the burning chamber tightness Boiler regulator - placed on upper boiler cover. The regulator is fixed to the boiler cover by stuck catch Chimney flue - made of /4 inch steel tube Ash pit - steel bottom of the burning chamber, ceramic ash pit added (working temp. 00 F) and additionally covered by refractory concrete Boiler door - produced of high quality steel, insulated with Nobasil thermal insulation and inside covered by refractory concrete layer. Also protected with heat-resisting fiberglass cord. EKO advantages Orlan boilers are produced as: ORLAN SUPER with cooling coil and mechanical cleaning device efficiency % (ORLAN -%) ow exploitation costs easy and simple service small quantity of ash one loading for hours power range from kbtu up to kbtu power modulation from 40 00% adapted for forced (pump) system equipped with electronic regulator and room temperatur sensor nature friendly produced of boiler steel 4
Boiler construction 4 4 0 Boiler construction. Chimney flue. Heat exchanger cleaning cover. Chimney flap 4. Hot water exit. Thermometer sensor. Safe guard thermometer sensor. Boiler controller. Upper door. Closing/opening door handle 0. Loading chamber (wood gasification) 0. Fan flap. Fan. Fan casing 4. Nozzle (refractory) 4. Secondary air adjustment. Combustion chamber. Lower door. Smoke tube heat exchanger. Primary airflow 0. Flue gas exit. Heating water entry. Drain valve. Secondary airflow 4. Water grate. Thermal insulation. Ash pit
Boiler dimensions Boiler dimensions scheme Boiler type Power range Weight Height Height of heating water exit Height of heating water entry Height of outlet valve Height of chimney flue Width including handle Width including casing Depth Hot water exit Diameter of chimney flue Diameter of hot water exit Diameter of hot water entry Kind of connection Diameter of drain valve Water capacity Volume of loading chamber (gasification) Power consumption Moisture of wood: - recommended - acceptable Maximum log diameter Maximum length of logs Average temperature of flue gas Max. working pressure Required chimney draught Voltage / frequency ORLAN kbtu Lb A inch B inch C inch D inch E inch F inch G inch H inch I inch Jmm inch inch - inch Gal Gal W % % inch inch F PSI Pa V/Hz 00. 4....4 4.. 4....0.0 thread 0. 0 0 40.0. 0.0 4.. 4....0.0 thread 0. 4 0 40-0- 0 0 0 0.... 4. 0... 4.0... flange 0. 4-0 V/0Hz 0 0.... 4. 0... 4.0... flange 0. 4
Boiler sizeing ORLAN boilers may be used for heating any kind of building. They are mostly used in one-family houses, drykielns, workshops, halls, or greenhouses. However, boiler placement is not limited to these applications; the above are just examples of where ORLAN boilers have worked with success. Selecting a boiler that ad- Heated surface [m ] height,m 00 0 00 0 00 0 00 40 400 0 00 0 00 0 00 0 0 0 40 40 equately fits ones output is very important. An improperly chosen boiler may subject the end-user to unnecessary expen-ses during boiler usage. Boiler output should be based on a building's heat demand, calculated by a qualified central heating designer. To select the appropriate 0 buildings well insulated buildings middle insulated buildings without any insulation boiler, the a/m calculated value should be increased by 0%. If this calculation isn't performed, boiler sizing Boiler sizeing may be chosen using the heat factor in relation to m of 0 building cubature. Heat factor values should be determined as 0-0 W/m depending on heat insulation. REMARK! 0 The scheme is only an example and New Horizon is not responsible for the wrong boiler choice.
STANDARD RK 00 R4E Regulator. Master switch. Boiler temperature indicator. Boiler fire-up mode indicator 4. Boiler overheating indicator. Room thermostat indicator. Boiler thermostat knob. Circulating pump indicator. Fuel shortage indicator. Room thermostat knob 4 STANDARD type boilers are equipped with RK 00 R4E enabling: Interaction with circulating pump Interaction with room temperature sensor, installed in the room and connected with the boiler regulator by two-strand wire Modulation of fan rotation Boiler output adapting to actual weather conditions Interaction with EUROSTER room thermostat Each boiler is able to work without room temperature sensor as well. RK 00 R4E Regulator Basing information about boiler assembly. Boiler placing. Boiler can be placed in the heating room, basement, or in an outside wood storage building. There should be enough space to accommodate fuel storage for the whole heating season.. Boiler start-up rules Each boiler should be connected to the heating system of which the heating capacity equals that of the boiler output. To protect the boiler against low-temperature corrosion the enduser should assure return temperature does not reach lower than F. It is possible by installing of four way mixing valve. Boiler has to be connected to the chimney duct in the smallest distance possible. Chimney duct should be insulated to prevent condensation (low exhaust temperature). The chimney should have the section and height assuring required chimney draught.
. Outdoors temp. sensor. Feeding water temp. sensor. Four-way mixer DUOMIX C, DUOMIX AO, DUOMIX P, DUOMIX Z 4. MK.CS assisting drive. Circulating pump. Room temp. sensor. Boiler. Heater. Operational water heating 0. Differential valve. Compensating vessel. Exit for warm operational water. Cold water entry 0 M 4 Boiler interaction with four-way mixing valve Mixing function is related to necessary temperature changing in central heating system considering outside temperature changes. For proper boiler operation, a suitable high temperature inside of gasification chamber is needed; then the water temperature upon boiler exit will achieve 40-0 F. Using four-way mixing valve enables to mix adequate water quantity, heated directly by the boiler, together with returning water from the system. As the result, the proper water temperature in the boiler is attained. Boiler protection from low temperature corrosion - is analogous to mixing function but also functions to increase temperature of the water returning from system by mixing of the water directly heated into the boiler. Preheating of warm operational water is related to necessary disconnecting of system during summer season. Water is heated in universal pre-heater linked with the boiler on gravitation. The central heating system should be closed during summer by mixing valve switching off, and then fast and efficient water heating is achieved. Example of boiler s connecting with four-way mixing valve And water heater If the boiler is connected into the forced (pump) system it has to be protected in case of power deficiency by adding power backup unit. If boiler operates in closed loop system temperature-pressure relief valve has to be installed! The best way is to connect a water heater into the heating system, which works together with boiler without pump service. This gravitational arrangement enables collecting of boiler minimal output during power deficiency. Low temperature corrosion occurs if the internal boiler walls are in contact with combustion gases having a lower temperature than the temperature of humidity causing condensation of the combustion gases. If there is more acetic acid into condensate, the low temperature process is more intensive. Boiler interaction with operational water heater To protect the boiler against overheating, the collector is needed to gather minimal theoretical boiler output on gravitation. ORLAN boiler model 40 0 0 Heat collector output kbtu kbtu kbtu. kbtu Recommended mixing valve diameter DN, DN DN, DN 40 DN 0 DN 0, DN For this purpose, the best way is to use operational water heater together with single function boiler without charging pump. By this gravitational connection, the system takes over the minimal boiler output in case of feeding shortage. Recommended volume of the operational water pre-heater OKCV 4 gal OKCV 4 gal OKCV gal OKCV gal
Boiler connection scheme - examples Connection scheme of two boilers working in cascade 4 R 0. ORLAN boiler. MK.CS mixing valve drive. Circulating pump 4. Differential valve. Operational water heater. Compensating vessel. Exit for warm operational water heater. Cold water entry. Four-way mixing valve DUOMIX C (DUOMIX AP, DUOMIX A0, DUOMIX Z ) 0. Outside temperature sensor Boilers connected in cascade enables the heating of bigger buildings. Boilers should be of the same output. Such a system gives better possibilities of heat source dynamics than a system with only one boiler. Particularly in "transition period" (springtime or autumn) boilers may be 0. ORLAN PLUS, SUPER with A 000 regulator. LADDOMAT thermoregulator. Accumulation tanks 4. Mixing valve drive LADDOMAT CWU. Heating system exit. Three-way mixing valve. Opened compensating vessel. Circulating pump Connection scheme of heat accumulation system 0 LADDOMAT CWU 4 0V 0V Connection scheme of the heat accumulation set with one vessel 0 M M 4. CZ04 room temperature sensor 0. CZ0 outer temperature sensor. CZ0 feeding water temperature sensor. ORLAN PLUS, SUPER with A 000 EV regulator. LADDOMAT thermoregulator. NAD, NADO accumulation tank 4. Electrical heater. Three-way mixing valve MIX C (MIX BP, MIX AP, MIX P). Circulating pump. CZ04 room temperature sensor. Heating system exit. Mixing valve drive 0. Opened compensating vessel. CZ0 outer temperature sensor. Mixing valve. CZ0 feeding water temperature sensor serviced alternately. Boilers with such a connection enables for its utilization with the output close to nominal, which warrants boiler longer durability. Heat accumulation tanks allows for boilers better adjustment according to actual weather conditions. In transition period (the spring, autumn) any boiler without heat accumulation set is switched on and off very often. If the set is connected, the boiler works constantly and the energy is lost into the vessels. Each boiler switching on and off means fuel losses. It may be avoided if the heat accumulation set is used. Simultaneously, in the transition period (the lowest temperature in winter time) the accumulation set helps to reheat the whole central heating system. Also it should be mentioned that few heat sources such as solar collector, heating pump, or similar may be connected to the heat accumulation set.
Additional equipment Wood hydrometer The hydrometer is needed for measuring of wood proper humidity during fuel purchasing but also for current control of stored wood. Boiler fired with wood of proper humidity warrants complete and correct fuel utilization. Long term use of inappropriate wood causes the onset of tar on boiler internal walls, which causes difficulty in correct boiler operation. Wood hydrometer Draining valve ORLAN additional equipment Thermal safety cooling device 4 To protect the boiler against overheating, any collector is needed to collect the heat surplus. For this purpose, the best way is to use any device able to work on gravitation such as water heater or heat accumulation tank. Boiler connecting scheme with thermostatic draining valve There is also a new solution, accessible only in ORLAN, where a TS 0 thermostatic draining valve is con-nected (produced by Honeywell).. ORLAN SUPER. Opened compensating vessel. Radiator 4. Thermal safety device. Four-way mixing valve. Circulating pump. Difference valve If the water excess temperature of 00 F the draining valve opens the cooling water flow (from water-pipe network) through the thermal cooling heat exchanger, built-in the boiler upper part. If the thermostatic draining valve is used there is no need to connect any other heat collector on the central heating system. The solution with draining valve is recommended when there is no place for placing of water heater and also when the warm operational water is heated in other device (e.g. in flow water heater).
Additional equipment LADDOMAT thermoregulator. RS -- circulating pump. Return temperature indicator. Heating water temperature indicator 4. Mixed water temperature indicator. ¼ IG ball valve. Thermostatic valve. Automatic valve for regulation of gravitation circle. Deposit collector. Exit for filling out LADDOMAT basing elements Laddomat is a charging unit for a solid fuel boiler to a storage tank with hot water heater and mixing valve for the heating system. Laddomat enables the boiler to attain a proper boiler working temperature in a very short time. Charging is continued by means of a slow flow of hot water. Laddomat works automatically on the condition that pump switches on / off automatically. During the final part of the burnout, Laddomat charges the storage tank fully due to the unique thermal valve, which closes the bypass opening completely. Laddomat works efficiently during all stages of the boiler operation. When the fire has gone out, Laddomat makes use of the remaining heat in the boiler and ember by the self-circulation of hot water from the top of the boiler into the storage tank. Energy is stored in the tank instead of being lost through the chimney. In the event of a power failure Laddomat starts charging the container immediately by self-circulation. 4 LADDOMAT 4 The same happens if the pump breaks down. Reverse circulation is prevented during periods of non-firing, which means almost no loss of heat. 4 Heating medium flow by Laddomat Stage Boiler fire up, temperature in the heating system lower than 0 F Stage Heat accumulation charging begin, heating medium is mixed into termo regulator Stage Full charging, heating medium from boiler feeding is mixed with secondary medium in small quantities Stage 4 Discharging of energy from the boiler during power failure