Do-it-yourself solid fuel gas generator boilers. DIY gas generator boiler

10 YEAR WARRANTY FOR THE FIREBOOK!!!

WORKS ON ALL TYPES OF SOLID FUEL!

Execution options: single-circuit, double-circuit (heating + hot water supply), universal pellet (pellets/firewood/coal/briquettes).

Based on Cosmos boilers of all modifications, we produce a modular boiler room "Galaktika" for installation on the street.

The flagship of the enterprise is a solid fuel gas-generating pyrolysis boiler long burning"Cosmos" KMV (multi-fuel hot water boiler) with stainless steel firebox at a very reasonable price.

You will be pleasantly surprised by the ease of achieving and maintaining a comfortable temperature in the house, the efficiency and low cost of installing the Cosmos boiler.

Operating temperature range for coolant supply to the system from 30 to 95 °Cwithout additional equipment.

Duration of burning wood at low loads is up to 12 hours, coal up to 24 hours. If you are already tired of being on duty at a constantly dying boiler or are planning to install a solid fuel boiler, then you have found the boiler you were looking for.

The thin-walled design made of heat-resistant, corrosion-resistant stainless steel allows heat to be transferred directly to the coolant with minimal losses. Have you seen a burnt kettle or samovar? No? So: thick walls of the firebox, especially fireclay, act as thermal insulation between the heat source and the coolant, which in turn reduces the efficiency of the boiler. The solid fuel pyrolysis boiler "Cosmos" heats up the coolant VERY QUICKLY. Thanks to the patented design, the boiler has an efficiency of 89% and is able to withstand operating pressure up to 5 atm. and operating temperature up to 123 o C!

Easy to maintain, reliable, durable. The use of heat-resistant stainless steel provides unsurpassed resistance to corrosion. The Cosmos pyrolysis boiler operates on both dry and wet wood.

This is how the boiler, which is already seven years old, works. Work at -30 o C

Boiler for any weather from -50 to +15 ºС!

Ease of operation allows even a person who has never had a clue about the existence of solid fuel boilers to cope with it.

The Cosmos pyrolysis boiler is very lightweight, making transportation and installation easier.Mounted in the boiler room, in the wall or outdoors.

Running around with firewood and being on duty at the boiler is a thing of the past!

Before you do it for yourself right choice, read very carefully the technical characteristics of the boilers you are considering and you will find many advantages of the Cosmos boiler in comparison with them.

• Automated installation for burning solid fuels.
• Automatic feeding: pellets, coal.

The history of the appearance of the solid fuel boiler "Cosmos" KMV

The unique performance indicators of the proposed boiler are the result of many years of work by engineers of the Termopass research and production enterprise to improve the design aimed at optimizing combustion processes in the combustion chamber. The first solid fuel pyrolysis boilers long-burning "Cosmos" have already served grateful users 20 years without complaints.

The photo shows the boiler of the first series "Cosmos-30". In operation since 2000

No wonder the plant gives 10 years warranty for solid fuel boilers "Cosmos". The reliability of Cosmos boilers has been tested and proven both in the temperate Belarusian climate and in the severe Yakut frosts, where more and more people prefer this particular solid fuel boiler. The operation of a gas generator boiler is based on the principle of pyrolysis fuel combustion, the essence of which is that under the influence of high temperature and in conditions of lack of oxygen, solid fuel decomposes into the volatile part - the so-called pyrolysis gas and the solid residue is charcoal (coke). This process is exothermic, involving the release of heat. Pyrolysis boilers "Cosmos" are produced with a power of 12, 15, 18, 25, 30, 35, 40, 50, 60 and 90 kW, which allows them to be used in both residential buildings so in production premises area up to 900 m². The power sufficient to heat a building in the climatic conditions of the Moscow region is considered to be 1 kW per 10 m². But this figure varies depending on the height of the ceilings, the overall heat loss of the building, etc. Based on the Cosmos boiler, it is also produced universal pellet boiler KMV with automation, working both on all types of pellets (based on the composition of raw materials, fraction, humidity), and onany firewood.

The uniqueness of the solid fuel boiler "Cosmos" KMV

So what is unique about this boiler? The firebox is made of heat-resistant stainless steel with a chromium content of 18%, whichhas high corrosion resistance when used in organic acidic and other aggressive environments, and has scaling onset temperature∼+760ºC , which makes it possible to resist burnout at maximum and low-temperature corrosion at minimum power, sinceWhen gasifying fuel at minimum power, tar and acids are released, which are very aggressive environment. Thanks to this, long-burning solid fuel pyrolysis boilers “Cosmos” are able to operate in a “squeezed” low-temperature mode for an indefinitely long time without the risk of leakage due to structural failure. Since the entire firebox is washed by the coolant, it turns out that the temperature of scaling is simply unattainable. Watch the video:

In this video, we place a plastic glass of water in the firebox. Thin firebox walls made of high-quality acid-resistant stainless steel are one of the main advantages of our boiler!

Below are some parameters of the most popular pyrolysis boiler "Cosmos-35" with a nominal power of 20 kW, for most of which it has no equal.

Test report KMV-20.

Smoldering combustion mode.

Advantages of the solid fuel boiler "Cosmos" KMV

If you do not heat the premises regularly, for example a dacha, and come only on weekends, then best option You won't find it. For example, "Cosmos-18" at a maximum power of 18 kW warms up the heating system from 0ºС to 60ºС with a coolant volume of 100 liters and normal circulation in less than 30 minutes from the moment of ignition; after reaching a comfortable temperature in the house, 5 kW is sufficient.

For conventional steel solid fuel boilers, the minimum return temperature must not be lower than +60ºС, otherwise the firebox will burn out. The KMV pyrolysis boiler operates from +30ºС at supply. Why is there more than 60ºС in the supply if it is +5ºС outside, and where should the excess heat be put? In the windows? Not every very expensive solid fuel boiler with complex system controls with reserve tanks or cascade schemes, which use several boilers of different power to achieve the required power in frequently changing weather conditions. And the more parts there are in the device, the higher the risk of failure of at least one of them, and the frost will not wait until the technician arrives with the necessary spare part (and it’s good if it is in stock and not on order in a couple of weeks). .. :).

Very often in winter period some rooms in the house are mostly empty and only need to maintain a positive temperature in anticipation of guests. This is where regular radiator taps with a thermal head come to the rescue. Reducing the temperature in some rooms will not make others hotter. The boiler itself will compensate for the drop in energy consumption. At the same time, the operating time will increase and will allow you to save fuel.

Pyrolysis boiler "Cosmos" KMV. Boiler operation.

Design of the Cosmos boiler KMV

The firebox has a cylindrical shape, into which a grate revolution is inserted through the lower door, which acts as a blower. It is made of the same stainless steel as the firebox. During operation of the boiler, very little ash is formed, and it is very convenient to remove it from under the grate while the boiler is operating. This made it possible to do without the usual ash drawer.

Thanks to the patented method of strengthening the firebox, it is not subject to temperature deformation, which made the design less material-intensive and, as a result, the weight of the 18 kW boiler is only 100 kg. Between the firebox and the body there is insulation, thanks to which heat is not wasted. In this case, the boiler can be installed both indoors (boiler room) and outside. Small dimensions and weight greatly facilitate transportation and installation. No special foundation is required in the boiler room. The heating system can use a battery tank and a boiler indirect heating for getting hot water for water supply, produced by NPP "Thermopass".

The shape of the firebox is ideal for extracting heat from the entire surface, so the Cosmos pyrolysis boiler works clearly and predictably, maintaining the set temperature until the last ember. Even when the wood burns out, the coals still give off heat for a very long time, which continues to warm the coolant. It is enough to stir the ash, lay a new batch of firewood on the smoldering coals, open the ashpit slightly and the fire flares up again! It’s not easy to “miss” the fire in our cauldron! His vitality never ceases to amaze.

We take into account the wishes of the customer

Long-burning solid fuel pyrolysis boilers "Cosmos", at the customer's request, can be manufactured with both right- and left-handed doors. And also the supply pipe can be on the right or left.

Installation of the Cosmos boiler

The boiler can be installed in the following ways:

1. In a boiler room located in a building in three ways:

1) on the floor

2) on the brackets you can place the boiler at a convenient height for you and you won’t have to bend down when servicing.

3) mounted in the wall, with the front part of the boiler located inside the room and the chimney outside. In addition to significant space savings in the boiler room as well as increased fire safety, because the hot chimney does not pass through the wall; this installation has a very original aesthetic appearance.

2. IN autonomous boiler room ,

3. Next to the house under a canopy, which is very welcome by our clients. The duration of operation without additional loading allows it to be placed outside a heated room.This simplifies the installation of a chimney that runs outside and increases the fire safety of the building. Due to its miniscule weight, the boiler can be installed on any flat surface or hung on brackets to the wall.

An insulated sandwich pipe made of special stainless steel with a thickness of at least 0.8 mm should be used as a chimney.

The recommended pipe height to ensure the required draft is 6 m. The length of the horizontal section of the chimney when exiting through the wall to the outside should not exceed 1 m. No more than two turns of the chimney by 90 degrees are allowed.

For normal operation of the boiler, an insulated chimney, a safety group with a 1.5 atm valve, are sufficient. expansion tank and a circulation pump installed on the return line. When using a gravity heating system, a pump is not needed.

To ensure hot water supply, use in the system indirect heating boiler .

Burns any kind solid fuel

The design of the boiler allows you to burn any chopped or unchipped logs of dry or damp wood maximum length from 0.5 to 1.2 meters depending on the power of the boiler, pellets, coal, briquettes.

Additional loading can be done while the boiler is operating, without waiting for complete combustion of the fuel. Anyone who has made a fire at least once in their life can handle ignition.

Our experiment

We conducted an experiment: how much firewood fits into the firebox of the Cosmos-18 boiler. We used ordinary birch firewood.

Loaded them into the firebox

Then they weighed them.

It turned out that the firebox holds 21 kg of birch firewood. Based on calculations carried out by plant specialists, the power released coniferous species wood with a moisture content of 35% when burned is 2.6 kWh/kg. For birch firewood, this figure is slightly higher, but even if we count it as pine firewood, the Cosmos-18 boiler is capable of generating almost 5 kW/hour for 12 hours. 2.6 kWh/kg*21 kg/12 h = 4.55 kWh. In practice, this power is more than enough to maintain a comfortable temperature in a heated building. We checked: when it’s +5°C outside the window and +40°C on the boiler, then in an insulated house with the windows open it’s +27°C! What will you do if the batteries are at +70°C, but they don’t allow it below? specifications boiler? In our opinion, there are three options: 1) Fork out for additional equipment. 2) Steam with a broom like in a bathhouse. 3) Put out the boiler and dress warmly. By installing the Cosmos boiler you will receive a device capable of providing comfortable temperature in the house in any weather and at no extra cost.

Operational safety comes first!

During operation, the body and doors of the boiler heat up slightly, which prevents skin burns from contact with them with an unprotected hand.

Appreciate your time, coziness and comfort in your home.

The boiler is not furniture! Choose it according to its technical characteristics.

In the absence of gas, coal and cheap electricity, the problem of heat supply can be solved with the help of efficient heating systems operating on wood - logs, waste, pressed briquettes. Such units are gas-generating boilers, the design of which differs from that of conventional boilers that burn wood, coal and other solid fuels.

Operating principle and design of heating installations

Boiler of this type equipped with a firebox consisting of two parts:

• The first is the loading chamber, in which, with insufficient air, wood fuel decomposes into a solid residue (charcoal) and a volatile component, the so-called pyrolysis gas. The pyrolysis process occurs with the release of heat, which dries the fuel and heats the air entering the combustion zone.
• Secondary air is supplied to the combustion chamber. Mixing pyrolysis gas and oxygen at high temperatures causes the gas to ignite. During combustion, pyrolysis gas reacts with active carbon, due to which the flue gases entering the atmosphere contain virtually no harmful components.

Attention! Gas-generating wood boilers are characterized by low soot formation, so they need cleaning much less frequently than traditional solid fuel installations.

The main disadvantages of this heating equipment are energy dependence and restrictions on fuel moisture. The advantages include its ability to work on one tab for a long period - more than 12 hours.

These installations use logs with a diameter of 100-250 mm and a length of up to 450 mm as fuel. The dimensions of fuel briquettes should not exceed 300x30 mm. When carrying logs and briquettes, you can use small debris, the volume of which should not exceed 30% of the volume of the loading chamber.

Advice! The drier the fuel, the more power the unit will produce and the longer its service life.

Possibility of self-production of the unit

High prices for solid fuel pyrolysis equipment explain the desire of many consumers to make a gas generator boiler with their own hands, drawings and detailed description As a rule, they are provided in a paid version.

One of the schemes was developed by designer Belyaev and involves the creation of a unit capable of providing thermal power about 40 kW. Air acts as the coolant in this system.

To manufacture a pyrolysis type unit you will need: a sheet 4 mm thick and pipes, the wall thickness of which must also be at least 4 mm, profile pipes, rod with a diameter of 20 mm, asbestos cord, fasteners. For the manufacture of linings heating installation You will need fireclay bricks. To provide efficient work unit and its convenient operation It is necessary to purchase thermostatic automation and a centrifugal fan.

You can create a gas generator boiler with your own hands using the scheme of the inventor Yu.P. Blagodarov. The unit is called Blago.

This heating installation ensures long-term combustion of wood fuel with the formation maximum quantity heat.

Attention! In the Blago apparatus, the bottom of the fuel bunkers is completely covered with grates. This design helps high level heat of fuel combustion and a long combustion period with natural draft. This device also allows you to increase the volume of the fuel tank without reducing efficiency.

Important advantages of the Blago boiler are its energy independence and ensuring complete combustion of compounds of phenolic groups - resins, alcohols, essential oils.

The rails installed in the combustion chamber serve as excellent heat storage devices. Blagodarov's heating installations use logs, coal, sawdust, and peat briquettes as fuel.

Pyrolysis plants from small manufacturers

If you are unable to make a pyrolysis unit yourself, and imported models are too expensive, then you can purchase a small-scale production unit. In the latter case, you must follow a number of rules:

• Require a license to manufacture this equipment. A license is not a complete guarantee of purchasing reliable and effective products, but the risk of purchasing low-quality equipment is significantly reduced.
• Estimate appearance unit, quality of welds. If possible, you should look under the decorative trim.

Attention! For the internal walls of the installation, metal with a thickness of at least 4 mm must be used.

• If ceramics were used in production, then it is necessary to clarify the price of replacing the nozzle, which can be up to a third of the cost of the pyrolysis unit.
• Determine which heating system this equipment is intended for - open or closed.

Advice! The ideal option is to obtain feedback from a consumer who has been using this equipment for several years.

For example, Bastion gas generator boilers, according to reviews from owners, work quite normally in brick housing construction, even in regions with cold winters. Although the duration of combustion on one bookmark in winter is approximately 5-6 hours.

It is necessary to purchase with some power reserve. This is explained by the fact that consumers are not always able to obtain perfectly dry fuel.

Advice! When purchasing or creating a gas generator heating installation, you should remember that it is advisable to install units of this design in separate room. This is a solid fuel device, and when loading it, fuel fragments can scatter throughout the boiler room. Chimney for a 40 kW unit it must have a diameter of at least 200 mm. It must be insulated throughout its entire height.

There are still enough places on the country's map where only firewood and coal are available for the production of thermal energy. The only alternative may be electric heating, but there is not always a sufficient technical base to withstand the increased load, and the high cost of this type of heating is affordable for few.

The development of energy-saving technologies has made it possible to improve the operation of solid fuel boilers. Gas generator boilers (pyrolysis) were presented to consumers. The raw material for heat production in such boilers is firewood, pressed fuel briquettes, as well as various wood waste.

Buying such a mass-produced boiler will not be cheap, but it is possible to make a gas generator boiler with your own hands. This will cost much less and, ultimately, you will get a unit with a configuration and basic characteristics that are ideal for the heating system of the house.

What is

Pyrolysis is a process of deep decomposition of substances under the influence of high temperatures without access of oxygen with the formation of a large number of various organic compounds in the gas, liquid and solid phase. The composition of pyrolysis products depends on the feedstock.

Gas generator boilers have a two-chamber structure. In the first, pyrolysis of solid fuel occurs in an oxygen-depleted environment ranging from 200 to 800°C with the formation of wood coke and pyrolysis gas. The gas enters the second chamber, where it mixes with oxygen and burns, releasing a large number of energy. The exhaust flue gas passes through the heat exchanger, giving up its heat to the coolant circulating in the system.

In such a boiler, it is not the heat generated by the combustion of wood that is used, but the heat from the combustion of pyrolysis gas. The thermal decomposition of wood without air access occurs much more slowly than during combustion, which increases the efficiency of the gas generator by reducing the consumption of raw materials and increasing heat removal.

During combustion, pyrolysis gas reacts with free carbon, which leads to a deeper conversion of combustion products. Therefore, the smoke released into the atmosphere consists mainly of water vapor and carbon dioxide (carbon dioxide). Thanks to this feature, solid fuel gas generator boilers are able to recycle chipboard, fiberboard, rubber waste and polymer materials without prejudice to environment. Much less solid residue (coke) is formed than during conventional combustion, which shortens the period between cleaning the unit.

Design and main elements

Pyrolysis boilers are quite large devices. The loading chamber provides for the use of wooden blanks with a length of 38 to 45 cm and a diameter of 10 to 25 cm, and pressed briquettes from 3 to 30 cm. Woodworking waste (sawdust, shavings) is added to the firewood, but their quantity should not exceed 30% of the volume cameras. A simple device layout includes:

• loading chamber (also known as raw material preparation) – removal of residual moisture;
• gasification chamber – the process of pyrolysis takes place;
• grate - a partition separating the chambers;
• combustion chamber – equipped with nozzles for supplying secondary air;
• chimney system - removal of combustion products and heating of the coolant;
• built-in heat exchanger with direct and reverse coolant supply pipes;
• forced secondary air fan;
• sensors for adjusting performance indicators.

Increased aerodynamic resistance is created inside the apparatus, which requires the use of smoke exhausters or blower fans to create forced draft.

Pyrolysis heating gas generator boilers have a lining layer of refractory material in both chambers. fireclay bricks. It prevents the structure from heating up and reduces heat loss, and also helps create the necessary temperature conditions for pyrolysis.

Material basis of the project

Independent production of a pyrolysis heating boiler will require material costs, but they are several times less than the cost of an industrial design. Before starting work, you need to familiarize yourself with information about the diagrams and types of boilers, make calculations and select suitable option.

If difficulties arise with this or you are not sure of the correctness of the decision, you can use the services of companies specializing in calculations of heat-generating equipment. It will still be cheaper than a factory boiler.

Tools and materials

After approval technical project The collection phase of tools and material begins. To work you will need:

• DC electric welding machine;
• drill;
• Grinder;
• consumables (drills, electrodes, cutting wheel with a diameter of 230 mm and a grinding wheel with a diameter of 125 mm);
• personal protective equipment for safe work.

The material base of the project depends little on the chosen scheme. You need to have the following material:

• metal sheets with a thickness of 4 mm (for internal surfaces) and 3 mm (for the manufacture of the body);
• rolled pipes with a diameter of 57 and 159 mm, with a wall thickness of 3.5 and 4.5 mm, respectively;
• fireclay brick;
• professional pipes of various sizes with a wall thickness of 2 mm;
• fan;
• temperature and pressure sensor.

Some materials may be needed during the work, but they will not affect the cost and completion time.

Mechanical installation work

In order to make a gas-generating heating boiler, it is better to use the existing circuit, and if you have engineering skills, add or change it to suit your needs. The main thing is that the volume of the chambers does not change. Most often when handicraft production pyrolysis boiler using the diagram heating device Belyaev designed for a power of 40 kW.

According to the drawing, cut out the elements, and then use welding to connect them into finished design. Experts recommend equipping a gas-generating heating boiler with a limiter to control the air supply to the gas combustion chamber. It is a pipe with a diameter of about 70 mm and a length slightly exceeding the height of the body. The end mounted in the lower chamber is equipped with a damper at the end of the pipe at a distance of 40 mm from its wall.

The contour along which the coolant moves inside the device must be made with a bend to increase the contact surface and improve heat removal. Any suitable option will do, increasing the contact area of ​​the heat exchanger without affecting changes in the size of the chambers.

Pyrolysis heating devices are often calculated on the basis that the coolant will be air, not water. This does not require strict sealing of hot air supply pipes and eliminates the possibility of system freezing. After assembling the device, you need to test it and install it in place.

Installation and fire safety

Evidence of correct assembly is indicated by the output to the heat-generating device mode. This process should take a matter of minutes, and warming up the entire heating system should take no more than half an hour. There is also a rather sharp increase in temperature in the heated room.

When starting up for the first time, you need to establish the efficiency of the new unit. This indicator indicates the absence of deviations and shortcomings in installation work. It is determined by the state of the exhaust flue gases, which should not have the suffocating smell of carbon monoxide ( carbon monoxide). This condition must be met in all operating modes.

Gas generator boilers are installed in a separate non-residential premises that meets all fire safety requirements. They suggest:

• presence of ventilation (hole with an area of ​​at least 10 cm2);
• installation protective casing in front of the combustion chamber ( a metal sheet 2 mm thick);
• filling concrete foundation under a boiler or creating durable brickwork;
• the presence of a space between the wall and the boiler of at least 20 cm, as well as pieces of furniture and other structures.

The room must also have access to power to connect a fan. If it is not possible to supply electricity, you can install a long chimney. But then a problem arises with its fixation and the sufficiency of the resulting traction. Pyrolysis boilers have become a successful symbiosis of a rustic stove and progressive energy-saving technologies.

A rational solution to the problem of heating and waste disposal are gas generator boilers, which allow saving up to 50% of fuel. They are characterized by high efficiency and ease of use. The installations are widely used in all spheres of the national economy.

Inside the chambers, the fuel itself and the gas released during the combustion process burn. It is enough to buy gas-generating pyrolysis boilers to solve the problems of space heating, hot water supply, and solid waste disposal. They are also used for cooking. Heating equipment of this type is used by construction centers, lumberyards, agricultural enterprises, woodworking shops, and auto repair shops.

As reviews of the operation of long-burning boilers show, the maximum effect is achieved when loading dry solid fuel with a humidity of up to 20%. The operating life of the gas generator unit on one load is 8–24 hours. It is determined by the requirements for temperature conditions premises, local climatic conditions. Great importance have quality characteristics fuel, boiler firebox size.

Device, principle of operation

The basis for the operation of gas generating plants is the gasification of organic compounds due to thermal decomposition. An exothermic (with the release of heat) process occurs inside the boiler in the temperature range of 200–1200 °C with a deficiency of oxygen. The air entering the burner area is heated, heating and drying of the fuel improves. Contact of pyrolysis gas during combustion with active carbon ensures the purification of the outgoing smoke from carcinogens. In essence, gas generator boilers separate the fuel into two parts: a solid fraction and a gaseous substance. Then they are removed separately.

Structurally, gas generators consist of a two-chamber firebox separated by a grate. Inside the first, dry distillation (pyrolysis) of fuel occurs, in the second, the resulting gaseous substance is burned. Some boilers are designed to direct the combustible gas to the stove or electric motor. internal combustion. In the secondary combustion chamber, located under the fuel chamber, draft is created artificially; air masses are pumped from above. Oxygen supply from below or from the side is organized only in some models. All gas-generating boilers are equipped with a nozzle, air supply channels, controllers, a fan, water pipes, and a chimney.

Ease of use and safety are ensured by pressure sensors, thermostatic air mass regulators, safety valves, and emergency hot coolant discharge systems. Electronic control units make it possible to control operation and adjust a number of parameters at your discretion. Manufacturers offer models with remote control. Organization of adjustment is provided heating system through the Internet.

Installation

Warranty conditions for gas generators - professional installation. Boilers are considered potentially dangerous, therefore it is necessary to comply with fire safety standards and the requirements of the manufacturer's instructions. Basic Rules:

• boilers are installed in non-residential premises with a ventilation hole of 100 cm2 or more;
• distance from walls, furniture, household appliances, other objects - 0.2 m; if it is impossible to determine the degree of flammability of materials, it is doubled or protective screens are installed;
• a heat-resistant base is made of concrete, ceramics or metal - it should protrude beyond the perimeter of the boiler body on the side of the ash pan and the filling hole by at least 0.3 m, on other sides - by 0.1;
• a metal sheet measuring 0.5–0.7 m is laid in front of the firebox;
• strapping from steel pipes- the use of metal-plastic products is not allowed.

Thermal insulation of chimneys is required. It is prohibited to install unnecessary valves inside the chimney. The instructions of boiler manufacturers clearly indicate installation rules, requirements for additional equipment, and materials used. If they are violated metal constructions become deformed and fail.

Review of products of popular brands

Floor-standing coal-wood gas generator boilers Atmos (Czech Republic) depending on installed burner can operate on light oils and natural gas. The simultaneous use of two types of fuel (alternation) is provided. No conversion required. Gas generator units from Buderus (Germany) are distinguished by the availability of delivery of individual sections for completing boilers high power. It is permissible to “increase” the automation by the number of circuits. Volume combustion chamber allows you to load logs up to 58 cm long.

High-quality gas generators wood boilers produced by Dakon (Czech Republic) operate only on wood with a moisture content of less than 20% - up to 12 hours on one tab. Simply converted to work on diesel fuel or gas. Non-volatile units Bastion (Russia) operate with natural circulation, without pump. One stack of logs, up to 62 cm long, is enough for 6, or 10 hours - in smoldering mode. Single-circuit gas generator BTS (Ukraine) operate on raw firewood and wood waste of any quality. All models move easily on wheeled legs.

Equipment Attack (Slovakia) - modern design and 12 hours of operation on one tab. The gas generator firebox DP 95 is designed for logs up to 1 m long. The only drawback is the many errors in the descriptions in Russian. Solid fuel pyrolysis boilers Defro (Poland) can serve as an additional reserve to other heating systems. Boiler houses with a capacity above 1000 kW are organized on their basis.

Advantages and disadvantages

The popularity of gas generating units is provided by the following advantages:

1. high efficiency - up to 95%;
2. the ability to regulate combustion processes;
3. complete combustion of fuel - minimal soot formation, no environmental pollution.

Flaws:

1. energy dependence - there are gas generator boilers that require connection to the electrical network;
2. demands on the moisture content of solid fuel - there are models that do not operate on raw wood;
3. high price of a solid fuel boiler - the payback period is 3–5 heating seasons;
4. the need to organize return heating - the problem is solved by installing a mixer;
5. the impossibility of automatic fuel supply is a drawback of the designs of solid fuel boilers of all types.

In search of an alternative source of energy, it was realized that it is not necessary to extract gas in mines and then burn it in boilers and internal combustion engines; combustible gas can be extracted from industrial waste and wood. A gas generator, or as it is also called a gas generator, by burning local fuel - firewood, peat, charcoal, sawdust and other wood waste, as well as sometimes other organic residues - is capable of releasing/generating flammable gases such as CO, CH4, H2 and others. There are several options for using the resulting gas, but in any case, each device is based on the principle of a gas generator. We will tell you in this article how a gas generator works, what elements it consists of, and what processes take place inside it. We will also consider options for further use of the obtained gas and places where such units can be installed.

So, what are the options for using the gas produced in the gasifier?

First - flammable gas is directed to gas stove in the kitchen and is used for cooking. The second is that the flammable gas is burned immediately in a pyrolysis heating boiler with a gas generator; accordingly, it is used for heating a house or greenhouses. By the way, such boilers can be called gas boiler wood-fired, solid fuel pyrolysis boiler, wood-fired gas generator boiler. All of them can be used both for domestic needs and for heating huge industries and workshops or enterprises. Third, flammable gas can be sent to an internal combustion engine, which serves as a drive pumping station or electricity generator. A wood-burning gas generator makes it possible to obtain electricity in those regions where it is not possible to install power lines, lay a gas pipeline, and the supply of gas in cylinders is difficult. In addition to autonomy, gas generators have other advantages, which we will reveal below.

Advantages and disadvantages of gas generators

As an example, let's look at the advantages and disadvantages of gas-fired heating boilers. Pyrolysis boilers belong to the solid fuel category, but differ significantly from conventional wood or coal stoves, where the usual process of fuel combustion occurs.

Advantages of gas generator boilers:

• The efficiency of gas generator boilers is in the range of 80 - 95%, while the efficiency of a conventional solid fuel boiler rarely exceeds 60%.
• Adjustable combustion process in gas generator boiler- one stack of firewood can burn from 8 to 12 hours; for comparison, in a conventional boiler, combustion lasts 3 to 5 hours. In gas-generating boilers with top combustion, wood combustion lasts up to 25 hours, and coal can burn for 5 - 8 days.
• The fuel burns completely, so you don’t have to clean the ash pan and flue often.
• Due to the fact that the combustion process can be adjusted (power is adjustable in the range of 30 - 100%), the operation of the boiler can be automated, such as a gas or liquid fuel boiler.
• Blowout harmful substances into the atmosphere from the gas generator is minimal.
• Gas generator boilers are more economical than conventional ones.
• Fuel for gas generators does not have to be dried to 20% humidity; there are boiler models in which wood can be used with up to 50% humidity and even freshly cut wood.
• Possibility of loading unsplit logs up to 1 m long and even longer into the boiler.

• In addition to firewood and wood industry waste, rubber, plastic and other polymers can be recycled in pyrolysis boilers.
• High safety of the boiler compared to a conventional one solid fuel boiler is provided by automation and the materials from which the unit is made, and especially the combustion chamber.

If we talk about gas generators that are used to produce electricity, they have exactly the same advantages, such as environmental friendliness, efficiency, high efficiency, high octane number 110 - 140, versatility in terms of fuel used and greater efficiency in winter.

Disadvantages of gas generator boilers:

• The price for a gas generator is 1.5 - 2 times higher than for a conventional solid fuel boiler.
• For the most part, gas generators are energy-dependent, since a fan is used to suck in air, but there are also models that can operate without electricity.
• If you use a gas-generating boiler at a power below 50%, unstable combustion is observed - as a result, tar precipitates, which accumulates in the flue.
• The heating return temperature should not be lower than 60 °C, otherwise condensation will form in the flue.
• Typically, gas generators are demanding on fuel moisture, but as mentioned above, there are models in which you can burn even freshly cut wood.

No other significant deficiencies of gas generators were identified.

By the way, gas generators are not such a new invention. Back in the middle of the last century, when most of Germany's oil resources were used for military use, firewood was used as fuel for cars. Even on trucks gas generators were installed. Modern units have not gone too far in their design, but, nevertheless, have been thoroughly improved.

The principle of operation of a gas generator - gas generator

In a gas generator or gas generator, combustible gas is produced from solid fuel. The main secret is that air is supplied to the combustion chamber, the volume of which is not enough for complete combustion of the fuel, while maintaining a high temperature of about 1100 - 1400 ° C. The resulting gas is cooled and sent to a consumer or an internal combustion engine if, for example, it is planned to produce electricity. We will consider in more detail the principle of operation of the gas generator below, specifying which process occurs in which element of the unit.

The device of a gas generator on wood

Let's consider the device of a gas generator for household use. I would immediately like to note that pyrolysis boilers with a gas generator differ from the proposed scheme, since gas combustion occurs inside the boiler in the second combustion chamber. We will consider only the gas generator itself, the output of which produces flammable gas.

Gas generator housing made of sheet steel and has welded seams. The most common body shape is cylindrical, but it can also be rectangular. The bottom and legs on which the gas generator will stand are welded to the lower part of the body.

Bunker or filling chamber serves to load fuel inside the gas generator. It is also cylindrical in shape and made of mild steel. The hopper is installed inside the gas generator housing and secured with bolts. On the hatch cover leading to the bunker, an asbestos seal or gasket is used on the edges. Since asbestos is prohibited for use in residential premises, there are models of gas generators whose lid seals are made of a different material.

The combustion chamber is located at the bottom of the hopper and is made of heat-resistant steel, sometimes inner surface The combustion chambers are finished with ceramics. Fuel combustion occurs in the combustion chamber. In its lower part, resins are cracked, for which a neck made of heat-resistant chromium steel is installed there. Between the body and the neck there is a gasket - a sealing asbestos cord. In the middle part of the combustion chamber there are air supply tuyeres. Tuyeres are calibrated holes that connect to an air distribution box connected to the atmosphere. The lances and distribution box are also made of heat-resistant steel. Installed at the outlet of the air distribution box check valve, which prevents flammable gas from escaping from the gas generator. To increase engine power or to be able to use firewood with high humidity (more than 50%), you can install fan, which will force air inside.

Grate serves to maintain hot coals. It is located at the bottom of the gas generator. Through the holes in the grate, ash from burnt coals falls into the ash pan. So that the grate can be cleaned of slag, its middle part is made movable. A special lever is provided to rotate the cast iron grate.

Loading hatches equipped with hermetically sealed lids. For example, the upper loading hatch tilts horizontally and is sealed with asbestos cord. The lid mount has a special shock absorber - a spring, which lifts the lid in the event of excess pressure inside the chamber. There are also two loading hatches on the side of the hull: one at the top for adding fuel to the recovery area, the second at the bottom for removing ash. Gas is withdrawn in the recovery zone, therefore most often in the upper part of the gas generator, but it is also possible to remove gas from the lower part of the unit. Gas is withdrawn through a pipe to which the gas pipeline pipes are welded. It is not necessary to immediately remove the gas outside the gas generator body while it is hot; it can be used to heat and dry firewood or other fuel in the loading chamber. To do this, the outlet gas pipeline is laid in a ring around the chamber, between the gas generator body and the bunker.

Filter "Cyclone" And fine filter located behind the gas generator housing. They are made of pipes filled with filter elements.

Before entering the fine filter, the gas passes through cooler. And after the fine filter, the purified gas enters mixer where it mixes with air. And only then the gas-air mixture enters the internal combustion engine.

The sequence of movement of flammable gas after it leaves the gas generator is shown more clearly in the diagram below.

Firewood or other fuel burns in the combustion chamber, being oxidized by air entering the combustion chamber through tuyeres from the air distribution box. The resulting flammable gas enters the Cyclone filter, where it is purified. Then it is cooled in a coarse filter. Then the cooled gas enters the fine filter, and then into the mixer. From the mixer, the resulting mixture enters the engine.

Process of converting fuel into gas

And yet: how is gas obtained from solid fuel? A certain transformation process takes place inside the gas generator, which is divided into several stages occurring in different zones:

Drying zone located at the top of the bunker. Here the temperature is about 150 - 200 °C. The fuel is dried by hot gas, which moves through a ring pipeline, as described above.

Dry distillation zone located in the middle part of the bunker. Here, without air access and at a temperature of 300 - 500 ° C, the fuel is charred. Acids, resins and other elements of dry distillation are released from wood.

Combustion zone located at the bottom of the combustion chamber in the area where the tuyeres through which air enters are located. Here, when air is supplied and a temperature of 1100 - 1300 ° C, the charred fuel and dry distillation elements burn, resulting in the formation of CO and CO2 gases.

Recovery zone is located above the combustion zone between the grate and the combustion zone. Here, CO2 gas rises up, passes through the hot coal, interacts with the carbon (C) of the coal and produces CO gas - carbon monoxide. Moisture from the fuel also participates in this process, so in addition to CO, CO2 and H2 are formed.

The combustion and recovery zones are called the zone active gasification. As a result, the generator gas consists of several components:

• Flammable gases: CO(carbon monoxide), H2(hydrogen), CH4(methane) and СnНm(unsaturated hydrocarbons without resins).
• Ballast: CO2(carbon dioxide), O2(oxygen), N2(nitrogen), H2O(water).

The resulting gas is cooled to ambient temperature, then purified from formic and acetic acid, ash, suspended particles and mixed with air.

Types of gas generators

There are three types of gas generators: direct gas generation process, reverse and horizontal.

They can burn semi-coke and anthracite coal - non-bituminous fuel. The design difference of this type of units is that air enters through the grate from below, and gas is taken from above. In direct process gas generators, moisture from the fuel does not enter the combustion zone, so it is specially supplied. Enriching generator gas with hydrogen from water increases the power of the generator.

Gas generators overturned or reverse process designed for burning resinous fuel - firewood, charcoal and waste. Their design difference is that air is supplied to the middle part - to the combustion zone, and gas is taken below the combustion zone - in the ash pan. Typically, in units of this type, the extracted hot gas is used to heat the fuel in the bunker.

Horizontal gas generators or transverse process gasification systems are distinguished by the fact that air is supplied to them from the side - in the lower part of the body, and it is supplied at a high blowing speed through tuyeres. Gas is sampled opposite the tuyere through a gas sampling grid. The active gasification zone in a horizontal process gas generator is very small and is concentrated between the end of the tuyere and the gas sampling grid. The start-up time of such a generator is much shorter, and it also easily adapts to changing operating modes.

Gas generator installation location

Gas generators and gas-generated heating boilers can be installed both inside residential premises, for example, in basements and ground floors, and on the street.

So called pellet boilers They are most often installed in the house, since loading them does not involve a large amount of garbage, and bags of pellets weigh little and can be stored somewhere near the boiler.

Gas generators using wood, and especially long wood, make sense to install on the street near the place where the firewood is stored. This way it will be possible to transport the firewood in a wheelbarrow directly to the boiler or gas generator and not lower it into the basement of the house. A boiler standing outside gets rid of dirt and ash in the basement. This is especially true for wooden houses, where there are increased fire safety standards. The outer casing of the boiler is made of stainless steel, which is not subject to corrosion. The boilers are also thermally insulated with bulk thermal insulation so that the ambient temperature has a minimal effect on the gasification process and the boiler start-up speed. The control system is housed in a steel casing under a cover to prevent it from being exposed to precipitation. The chimney has double walls. If you are interested in how to connect a gas generator if it is located on the street, then the answer is simple - pipes are laid in the ground so that they are minimally cooled if it is a heating boiler. The heating pipes approach the boiler from below, and the boiler itself is installed so that it does not freeze during long breaks in use.

By the way, as already noted, the duration of the fuel combustion process in the boiler can be from 12 hours to up to 25 hours. Depending on the power of the boiler and the area of ​​the heated room, it will have to be heated once every two days, and sometimes once a week. To preserve the heat generated by the boiler for such a long period, a heat accumulator is used.

Do-it-yourself wood-burning gas generator

There is nothing super complicated about making a gas generator with your own hands. Many people use such a unit for household needs or install it on a car. Before you start making a gas generator yourself, you need to familiarize yourself with the principle of its operation and choose a suitable operating scheme for yourself.

You will need a barrel, pipes or an old radiator battery, fine and coarse gas filters, and a fan. On the other hand, the set of elements can be very different, it all depends on the imagination of the performer.

Below watch a video example of a gas generator self-made.

Gas generator circuit:

You can find both photos and installation drawings on the Internet. gas generators and pyrolysis boilers. There are even craftsmen who take a ready-made, proven boiler as a basis and completely replicate it at home. It turns out much cheaper.

The difference between a pyrolysis boiler and a conventional gas generator is that it consists of two combustion chambers: in one, fuel burns and gas is formed, and in the other, gas burns and a heat exchanger is located. We have already examined the design and principle of operation of the gas generator; add only a second combustion chamber, which should be located at the top, and a heat exchanger on top. Sometimes the heat exchanger is located on the side. Also don't forget about different types gas generators, so that the second combustion chamber can be located not only on top.

When assembling the chimney, try to assemble it in the reverse order of the movement of smoke, so less nasty things will settle on its walls. It is better to make the chimney itself easily disassembled so that it can be easily and quickly cleaned. The space around the heating boiler must be free, as it heats up during operation. After installing the boiler, you will have to study its “habits” and choose the optimal operating mode for yourself, in which all the resins burn.

I would like to note that the gas generator can be considered not only as a burner of useful wood, but also as a waste disposer. In it you can burn the remains of linoleum, bags, bags, rubber, plastic bottles and other household waste.