Sounded Easy at First

A Coal stoker furnace or stove controls most operations including automatically feeding the coal. They are quite similar to any conventional oil and gas units and easily operated for extended periods of time. They commonly use rice coal but may use larger sizes like buckwheat. They can be used as primary heat, supplementary heat or have a dual set up with your existing oil/gas furnace.
User avatar
tsb
Member
Posts: 1797
Joined: Wed. Jul. 30, 2008 8:38 pm
Stoker Coal Boiler: Binford 2000
Hot Air Coal Stoker Stove: LL Pioneer top vent
Hand Fed Coal Stove: Saey Hanover II
Baseburners & Antiques: Grander Golden Oak , Glenwood # 6
Coal Size/Type: All of them
Location: Douglassville, Pa

Post Sun. May. 23, 2010 9:02 pm

I've burned coal for years. First hand fired, then I got a Leisure Line stoker. My house
is a big old grist mill with 2000 sq ft per floor. We heat two floors and the ground floor
basement is unheated. Old Houses
The stoker and hand fired stoves work well to keep the main living
floor warm and the heat rises to the bedrooms up stairs, but the bathrooms are cut off
from the heat unless the doors are alway open. It's tough to train quests and others to leave
bathroom doors open. Soooo I got the idea to build a small stoker boiler to heat the three
bathrooms and give the basement a little heat to help keep the floors warm. Can't be that
hard or time consuming. Oh yes it can.
Building the boiler was the easy and cheap part.
Sleleton.JPG
Fabricating is what I do for a living. The design was provided by a consultant that rents
office space form us. He dove right in and dreamed up a beauty.
Pipes.JPG
A pipe design with removable and reflective side panels. The balancing tubes are internal.
Cap Installed.JPG
The domed cap provides space for the bulk of the water and the domestic hot water.
Base.JPG
The removable base gave me access to weld the pipes and inner welds and the ability to
determine the location of the smoke pipe.
Side Panels on.JPG
The side panels have a polished stainless panel that faced the heat. The cap has a reflective panel also.
Test Fire.JPG
We insulated the body and skinned it with 409 stainless. Gave it a test fire and dragged it home.
This is where the fun and expense started.
Install Front.JPG
Not only was the SOB heavy as all get out, but if fit through the door with only a hair to spare.
Install Rear.JPG
My fingers are getting tired. I'll get to the fun part in a few hours.
There seems to be an extra picture that I can't get rid of. No matter.
Attachments
Shell Asembly.JPG
Coal -- It's not a hobby, It's an addiction.


User avatar
CoalHeat
Site Moderator
Posts: 8327
Joined: Sat. Feb. 10, 2007 9:48 pm
Stoker Coal Boiler: 1959 EFM 350
Hand Fed Coal Stove: Harman Magnafire Mark I
Baseburners & Antiques: Sears Signal Oak 15 & Andes Kitchen Range
Coal Size/Type: Rice and Chestnut
Other Heating: Fisher Fireplace Insert
Location: Stillwater, New Jersey

Post Sun. May. 23, 2010 9:48 pm

You've got me hooked...waiting for part 2!
BTW great job on the boiler, I wish I could build works of art like that.
Heating a circa 1832 farmhouse with a Harman Magnafire Mark I & a 1959 EFM 350 (heating DHW).
100% Oil Free!
"It's what we learn after we think we know it all that counts."

User avatar
brckwlt
Member
Posts: 2743
Joined: Tue. Jan. 27, 2009 8:32 pm
Stove/Furnace Make: Axeman-Anderson
Stove/Furnace Model: Rebuilt 1953 AA-130
Location: Sunbury, PA

Post Sun. May. 23, 2010 9:59 pm

thats great, looking forward to the second part as well.

GREAT JOB :up:
burning pea coal from harmony mine, picked up in my 2002 Pontiac "Coalfire"

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Rob R.
Site Moderator
Posts: 11343
Joined: Fri. Dec. 28, 2007 4:26 pm
Stoker Coal Boiler: EFM DF520
Hand Fed Coal Stove: Hitzer 50-93
Coal Size/Type: Lehigh Rice
Other Heating: Dad's 1953 EFM Highboy
Location: Chazy, NY

Post Sun. May. 23, 2010 10:24 pm

Very impressive!

What are you using for a stoker?

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Hambden Bob
Member
Posts: 6469
Joined: Mon. Jan. 04, 2010 10:54 am
Hot Air Coal Stoker Stove: Harman 1998 Magnum Stoker
Hand Fed Coal Stove: Blower Model Coal Chubby 1982-Serial#0097
Coal Size/Type: Rice-A-Roni ! / Nut
Other Heating: Pro-Pain Forced Air
Location: Hambden Twp. Geauga County,Ohio

Post Sun. May. 23, 2010 10:29 pm

The damned thing is a work of art! What's next,a knock-off of an M-1 Abrams Tank ?........Beautiful ! You have made my night. Thanx for fighting the current dumbdown trend in America. :clap:
Remember,There's No Sight Like Anthracite !......Hambden Bob

User avatar
tsb
Member
Posts: 1797
Joined: Wed. Jul. 30, 2008 8:38 pm
Stoker Coal Boiler: Binford 2000
Hot Air Coal Stoker Stove: LL Pioneer top vent
Hand Fed Coal Stove: Saey Hanover II
Baseburners & Antiques: Grander Golden Oak , Glenwood # 6
Coal Size/Type: All of them
Location: Douglassville, Pa

Post Sun. May. 23, 2010 11:00 pm

The stoker was the first real cash output. I got the grate from a well know stove maker.
The stoker blower and feed motor came from amazon online sellers. I made the stoker
framework, but the motors and grate were about $250.00. Ok, not so bad but we're just
getting started. Me and the local plumbing supply house became blood brothers. I'd stop
in every day after work, and they would tap a pint. I'm O neg but that did't cut any cheese with them.
The steel fittings for the supply and return lines, a circulator for the upstairs zones and one for the
basement dump zone, ouch this is starting to hurt. The zone valves, the aquastat, the over temp sensor,
the feeder low speed timer, the expansion tank, the auto fill, the check valve, the auto air bleeders, the
modine unit for the dump zone, yo this is really starting to get serious ! Now we have to get the domestic
hot water coil. Ouch !!!!!
The chimney in the picture has been there for 30 years unused. The mason that built the chimney for the
upstairs stove, made it a twin chimney for stability and you never know when you'll need another. He did
not cut the thimble. I figured, how hard could it be to cut in a 6 inch thimble ? Another blood bath. It only
took about two hours and a box of bandaids. I used a star chisel and a diamond wheel on a grinder to get
through the cement block shell. After that I laid waste to the clay liner with a ball peen hammer. Did a hell
of a job. I grouted the thimble with hydraulic cement. The stove pipe is more of the 409 stainless. The baro
damper is another $ 30.00 bucks.
Did I forget the baseboard units, the thermostats, the pex tubing, the shark bite fittings, the manual bleeders,
the pex support clips, wire ties, 24 volt transformer, copper tubing for the DHW, copper tubing to get to the pex,
boiler ball valves for drains, circulator isolation ball valves, JHC this is really getting serious.
Coal -- It's not a hobby, It's an addiction.

User avatar
jeromemsn
Member
Posts: 1089
Joined: Thu. Oct. 04, 2007 12:30 am
Hot Air Coal Stoker Furnace: Keystoker 90 dvc
Hand Fed Coal Stove: Harman elite fireplace insert
Location: Edwardsburg, Mi. 49112

Post Sun. May. 23, 2010 11:45 pm

WOW!!!!
The warmest people I know burn Coal! ©

User avatar
CoalHeat
Site Moderator
Posts: 8327
Joined: Sat. Feb. 10, 2007 9:48 pm
Stoker Coal Boiler: 1959 EFM 350
Hand Fed Coal Stove: Harman Magnafire Mark I
Baseburners & Antiques: Sears Signal Oak 15 & Andes Kitchen Range
Coal Size/Type: Rice and Chestnut
Other Heating: Fisher Fireplace Insert
Location: Stillwater, New Jersey

Post Mon. May. 24, 2010 7:12 am

Do you have any photos of the stoker assembly?
Heating a circa 1832 farmhouse with a Harman Magnafire Mark I & a 1959 EFM 350 (heating DHW).
100% Oil Free!
"It's what we learn after we think we know it all that counts."


User avatar
europachris
Member
Posts: 993
Joined: Sat. Dec. 09, 2006 5:54 pm
Stove/Furnace Make: EFM 350/Iron Fireman
Stove/Furnace Model: Custom bituminous burner
Location: N. Central Illinois

Post Mon. May. 24, 2010 7:19 am

Beautiful work! I think there will always be a percentage of people who have this "disease" most all of us here have - the burning desire to DIY something even if you can buy it in the store. Not because we are cheap, although thrifty would be a good description, but because simply it gives great pleasure to construct something that will stand testament to our existence. Oh, and the looks you get from people when you say "I built this" are just priceless! :P

I'm looking forward to being in your spot soon as I get my EFM boiler and Iron Fireman stoker refurbished and installed on a custom base I'm fabricating. But it's nothing close to the project you've undertaken!

Can't wait to hear how it heats.....although that's gonna be a while now, eh? Yesterday was 89 and humid, today is more of the same. A/C!

Chris
Economic Stimulus = Supporting your local Miners
I love the smell of Illinois bituminous in the morning.
Have you hooked a clinker today?

User avatar
tsb
Member
Posts: 1797
Joined: Wed. Jul. 30, 2008 8:38 pm
Stoker Coal Boiler: Binford 2000
Hot Air Coal Stoker Stove: LL Pioneer top vent
Hand Fed Coal Stove: Saey Hanover II
Baseburners & Antiques: Grander Golden Oak , Glenwood # 6
Coal Size/Type: All of them
Location: Douglassville, Pa

Post Mon. May. 24, 2010 7:57 am

I'll post a picture of the stoker with the next episode tonight.
Coal -- It's not a hobby, It's an addiction.

User avatar
AA130FIREMAN
Member
Posts: 1951
Joined: Sat. Feb. 28, 2009 4:13 pm
Stove/Furnace Make: axeman anderson
Stove/Furnace Model: 130 anthratube

Post Mon. May. 24, 2010 8:15 am

That is the cat's meow, well done! What is the BTU of the stoker mechanism you used ? I would think the BTU output would be greater in a boiler over the stove being the temperature differential is greater between the water and fire verses the stove temp. and the fire. Maybee not :o Guess the amount of surface area in the combustion area would come into play. Why don't the stove mfg. make fins like an air cooled engine to radiate more heat.

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SMITTY
Member
Posts: 11915
Joined: Sun. Dec. 11, 2005 12:43 pm
Stoker Coal Boiler: Patriot Coal - (custom built by Jim Dorsey, Taunton MA - RIP 4/18/13)
Hand Fed Coal Stove: Harman Mark III (SOLD!)
Coal Size/Type: Rice / Blaschak anthracite
Other Heating: Oil fired Burnham boiler
Location: West-Central Mass

Post Mon. May. 24, 2010 9:04 am

That thing is mint!!I'll bet it'll still be heating your place 100 years from now ... barring a coal ban ... :roll: :lol:
The laws that forbid the carrying of arms...disarm only those who are
neither inclined nor determined to commit crimes. ...Such laws make things worse
for the assaulted and better for the assailants, they serve rather to
encourage than to prevent homicides, for an unarmed man may be attacked with
greater confidence than an armed man."

- Thomas Jefferson, quoting 18th century criminologist Cesare Beccaria in "On
Crimes and Punishment."

User avatar
tsb
Member
Posts: 1797
Joined: Wed. Jul. 30, 2008 8:38 pm
Stoker Coal Boiler: Binford 2000
Hot Air Coal Stoker Stove: LL Pioneer top vent
Hand Fed Coal Stove: Saey Hanover II
Baseburners & Antiques: Grander Golden Oak , Glenwood # 6
Coal Size/Type: All of them
Location: Douglassville, Pa

Post Mon. May. 24, 2010 5:28 pm

Here is a picture of the stoker. It's a pretty basic carpet feeder. I bolted
the hopper to the feeder. This is so that if I have a flooding situation, I
can just unplug the feeder and blower motors, take off 6 bolts and the
whole feeder and hopper come off as a unit. If the water gets to the
electrical panel, we have more problems that can't be fixed by moving
anything.
Feeder.JPG
Hopper.JPG
E-Panle.JPG
But this post is to explain the " Time Vampire " aspect of this project.
Thanks to all the members that have posted topics and questions in the
boiler area here, I spent a good month just reading the ins and outs of
a coal boiler. Where to put the circulator, sizing the circulator, pex vs copper,
pex vs pex, flow rates, control devices, return loops, wiring diagrams, dump
zones, delta T , you name it, I read it. And I enjoyed every minute of it. All
the posts were helpful, but in the end, most decisions were made by what looked
about right and how it would fit in the space allowed. As you can see, the thrill of
threaded pipe fittings died out after the circulators.
So THANKS to all, past and present that post the helpful hints that make a project work.

Tom
Last edited by tsb on Mon. May. 24, 2010 7:21 pm, edited 1 time in total.
Coal -- It's not a hobby, It's an addiction.

User avatar
ceccil
Member
Posts: 1062
Joined: Sat. Mar. 15, 2008 11:33 pm
Stove/Furnace Make: Keystoker, Harman
Stove/Furnace Model: 90K, Mark III
Location: Elmira, NY

Post Mon. May. 24, 2010 6:22 pm

So what's the name of this beast going to be? Take your time and pick something that will represent the time and love that went into building it. Looks great. :up: :clap:
Jeff
Loyalty to the country always. Loyalty to the government when it deserves it. - Mark Twain

User avatar
Yanche
Member
Posts: 3032
Joined: Fri. Dec. 23, 2005 12:45 pm
Stoker Coal Boiler: Alternate Heating Systems S-130
Coal Size/Type: Anthracite Pea
Location: Sykesville, Maryland

Post Mon. May. 24, 2010 8:17 pm

Nice job, you obviously have done your homework and have excellent fabrication skills. I'm sure once it's put in service you will be asked or you will wonder what's the BTU produced by this boiler. With a little planning it's an easy measurement. You use the circulator as a flow meter. It's done by measuring the circulator differential inlet to outlet pressure and then looking up the corresponding flow on the circulator flow curve. So if you thing you would be interested in making such a measurement allow for it now. Put a tee before and after the circulator with shut off valves. Then it will be easy to hook up the pressure gauges. If you post what circulator you are using I'll illustrate how to do it and what gauges will work. From the photos it looks like Taco green.
Yanche
Alternate Heating Systems S-130
Stoker Boiler burning Anthracite Pea Coal


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