This is a copy of an e-mail sent to me which describes a number of melts, including a 17 pound cast iron melt, using the new upscaled version of my "Reil" burner. It is self explanatory. If you wish to contact any of the guys in this communication please return to my Forge and Burner Design Page to the section about the "Monster Burner" and there are e-mail links there. Thank you.
Thius additional communication was received from Rupert just prior to me posting this log;
I ran a test heat yesterday (first time in the rain) to confirm my suspicions. The melt I did was aluminum as the feature was to test the burner which I did inside (due to the rain) with the doors open for ventilation. The ceiling gets too hot when the burner is run at the higher pressures. After consulting with Robert, we decided to change the text on Donald's web page to show the correction, which reflects the operating range of the burner.
"The burner operated satisfactorily at fuel pressures from 10 psi and up to 25 psi. It was unstable at pressures below about 6-8 psi, and hasn't been tried above 25 psi yet."
Attached is a report submitted to our local email group by my friend Rupert
Wenig on a melt of iron in a Gingery gas fired crucible furnace, fired with
a modified Reil burner. The burner uses a 1-1/4" pipe for a burner tube,
and Rupert has spun a fitting for the bell, which allows him to adjust the
airflow in the burner. He has drilled the orfice #54.
<snip unrelated stuff>
Instead of writing about it,I am attaching a copy of my foundry
log. I will try to be more elaberate if there is anything which
is not clear.
RR.2, Box 1 Building an uniflow engine
Camrose, Alberta, Canada Bore 1.25"
T4V 2N1 Stroke 1.5"
email@example.com Flywheel dia. 7"
ICQ #32409359 Foundry Log
Date: 1 May, 1999
Pattern: 8" Lathe face plate
Metal: Cast iron- old auto exhaust manifolds broken up
Atmospheric conditions: Temp. +8 C, wind- slight
Bottle contents: about 1/3 full (100 lb. bottle)
I note propane quantity in bottle as it affects any possible freeze up
time. Some frost did show on the bottle during the last part of the heat. I
had thought of providing external warmth to the bottle but didn't.
Furnace settings used: propane pressure- 20 lb.
: air valve setting- about 3/4 open
Crucible used: #8 Starrbide
Amount of metal (cast iron) melted- 17 lb. wieghed after the pour was
completed and cooled.
Started the heat with a 5 min. warm up time at low flame to warm up the
crucible as it hadn't been used for a while then went to full heat and added
metal (1-2 lb.pieces) as the melt progressed. Things seemed slow at first
but the melting speed sure increased toward the end of the heat. Metal was
added according to the following time chart:
09:20 ignition time (crucible full of metal pieces)+ 1 crushed BBQ brickette
09:25 full heat
09:40 first sign of melting
09:55, 10:09, 10:14, 10:19, 10:23, 10:26
10:33 heat considered complete as the crucible appeared full but was fooled
by the grunge. I think I could have added a bit more metal.
Fuel consumption: about 10 lb.
Pour was a bit short of metal but left the casting in the green sand mold
to cool just in case the casting would be useable. It is. I removed it about
6 hrs later, then after another hour tried machine it. So far so good.
In a separate message to another member of our group, Rupert provided
details of his burner. The "D" mentioned by Rupert is the pipe diameter.
We have empirically worked out some relationships in these burners, which
seems to work for our purposes.
The burner pipe size is 1-1/4" black pipe 9D long. The coupling
(air inlet) is 1-1/4" by 2-1/2" (with air valve). The fuel
orifice (see my previous pictures for appearance) is spaced 1/2D
from the inlet end of the 1-1/4" pipe. There is no flame end
pipe. The burner is postioned tight into the furnace with about
1" of pipe on the tangent side inside the refractory.
The burner seems to operate satisfactory at fuel pressures from
15 lb and up to 25 lb. It is unstable at pressures below about 12
lb. I haven't tried it above 25 psi yet.
Other info in another message.
Rupert provided additional details about the orfice in his burner in yet
another message. We are using the Bordeaux modification to your burner.
Ruperts gas assembly consists of a 1/8" gas inlet tube into a 1/8" tee in
the center of the bell. The other end of the tee is supported by a capped
1/8" nipple. A brass plug is screwed into the tee, and is prepared as below:
Hello Robert and All,
Sorry about not including the jet info. I'm not sure if the
procedure makes a difference but I'll include it.
If you remember from the pictures I sent awhile back, my jet is
made from a brass hex plug. I drilled in from the threaded end
with a 5/32 drill until I was about 1/8" from the top. Then I
drilled through with a #54 drill. All drilling done from the
threaded end. Then I used a taper reamer to clean the hole (not
to enlarge it). Last I used a small countersink to remove only
the sharp jagged edge from the orifice hole on the top side.
Another member of our group (Bob MacDonald) has more or less copied Ruperts'
burner, and this is a report on his results, again in a Gingery furnace.
After reading about Rupert's success with his new burner, I decided to be a
copy cat. Assempled the pieces with two minor differences. I drilled the
oriface .050" as I didn't have a #54 and I didn't build the air valve.
Once everything was togather I put the burner tube in the furnace so the
end of the tube was at the wall mid point and light it. Well it didn't burn
worth a damn. Pushed the tube into the furnace untill the end of the tube
was almost even with the inner wall. The flame was now completly out of the
tube and it made such a sweet roar.
Foundry log follows
Propane pressure.. 20 Lb
Propane pressure.. 20 Lb
I think 19 minutes to melt 6 Kilo of brass is very respectable.
Bob "Damn those chips are hot" MacDonald
So many projects, so little time.
Shop located in Sunny Spruce Grove, Alberta
Yet another member of our group (Dale Gillespie) has built a mini crucible
furnace from two refractory lined 2 kg coffee cans. He assembled a mini
Reil burner by walking around a hardware store, screwing plumbing fittings
together until it looked right, keeping in mind the empirical relationships
we have established. I believe he used 1/2" pipe for the burner tube, but I
have only seen photos to date. He was able to make a melt of aluminum in 7
minutes from a cold start, and brought a casting he had made that afternoon
to our monthly meeting on Thursday night.
Hope you find this of interest. We hope to get photos and some of the above
details on our web site when time allows.
This is a fan letter - no response is required, nor is one expected.
Robert Grauman in Sunny Alberta
Edited With AOLpress
©Golden Age Forge
23 Nov 07