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Furnace burners potentially create more than enough problems for the hobby metal casting worker, it is not unusual to read about people who are attempting to build a furnace, only to be confronted with problems and frustration with a complex burner?

It is quite simple to construct a crucible furnace, but the stumbling block seems to be: "The burner". Why?

Problems seem to manifest themselves because:

For some reason, people choose to fabricate complex burners from detailed drawings without the skills, tooling and machining facilities in which the original designer employed during the design & building process.

With the necessary workshop skills coupled with a reasonable selection of equipment & tools, will have a marked effect on how well you, as a hobby foundry worker, will be able to construct the equipment required for the successful melting of metal.

There are no short cuts when it comes to building equipment for your hobby foundry, to cobble something together in a rough fashion is only asking for trouble in the future, it is well to heed the old trade school teacher quote:

"If a job is worth doing, you might as well do it properly in the first place"

He is right, you know.

You can learn how to build an effective simple furnace burner, which is well documented in the hobby foundry ebook "Metal Casting Made Easy" available at our web site. But to explain everything in detail here would take up far too much time & space.

Following is a simplified description:

The burner consists of a long plain black mild steel pipe. The burner end nozzle consists of an inverted cone. There is a mid section where a venturi is installed; the gas jet is located near the venturi.

The simple brass jet protrudes into the forced air stream, which travels through the burner tube. The gas jet orifice is quite large and operates under low pressure; the air delivered by the blower to the burner tube is low pressure, but moves at a high volume.

The burner design is simple, yet effective, but there are some components incorporated in the design that only require basic lathe turning skills. But general workshop knowledge is sufficient to build this item. There's no rocket science involved.

The blower consists of a second hand household vacuum cleaner (the type that has a second outlet for the hose connection that blows). The vac also has an electronic vari motor speed control, which enables a regulated low-volume airflow to be delivered during the burner start up phase.

This feature is MOST important during the furnace start up.

Does this burner work? You bet it does, the burner is capable of melting a 5 Kg (11lbs) charge of Aluminium from a cold start in less than 40 minutes.

The gas supply is provided from a Liquid Petroleum (LP) cylinder (Propane in the states) It is essential that the gas supply be controlled by an adjustable industrial diaphragm gas regulator gauge suitable for LP gas, there is no other SAFE way to regulate & deliver fuel gas to a furnace burner. A ball valve should be installed in line as an emergency shut off valve.

There's no reason to build & operate complex burners that require special size jets, and shrouds, which must be operated at a certain gas/air pressure? There is nothing more frustrating than an apparatus that won't operate as it should; why spend half the day mucking around with something that is an absolute pain to use, when you should be enjoying your metal casting experience!

The people who design & build complex burners for other's to copy, possess lathes, milling machines and many other expensive machine tools to build the burners, but if you choose to build it even slightly different to the original design specs, there is a good chance the burner just wont work properly!

To learn more about building hobby metal casting tools and equipment, visit: www.myhomefoundry.com A rich info resource centre for the hobby metal caster.This article may be reproduced as long as the URL links and reference remain.

Build Green for Lifelong Savings

Green building is a design process that grows out of a connection with the natural landscape. It is a set of informed decisions that considers the site and materials to reduce the cost, maintenance, and energy usage of the home. Conservation is central to the green building approach. Green homes are healthier, safer, more comfortable, and cost less to operate. They connect people to the land and community around them. Here are seven green building ideas:

1) Build a passive solar design.

Passive solar design for natural heating and cooling is practiced throughout the world under all climate conditions. As energy costs rise, it is critical to use building orientation, window placements, stone floors, roof overhangs, reflective barriers and other techniques to control natural solar energy.

In warm climates, face the broad side of the house to the north or south, to avoid excessive heat gain as the sun rises and drops in the horizon. Use deep overhangs or solar screens to shield glass areas from direct sun. Avoid skylights or greenhouse rooms, because they allow too much heat gain.

In colder climates, solar heat can be captured and stored in materials such as concrete or stone to be slowly released during the evening.

An open floor plan optimizes the effect of passive solar heating or cooling.

Doors and windows should be placed to catch the prevailing breeze and allow cross ventilation.

Lower inflow windows and higher outflow windows keeps air moving, as hot air rises.

A thermal chimney uses a hot zone, such as a glass cupola with windows or vents, to create rising air currents to pull air through the building.

Double glass panes provide an insulating air space between the panes, reducing heat transfer.

The metal oxide coating on Low-E (emissive) glass helps to keep solar heat out, and interior heat in.

2) Ventilate attic spaces.

In hot climates, attic spaces can accumulate heat, transferring it to living areas below. AC ducts located in the attic will absorb this heat.

In cold climates, moisture can accumulate in unventilated attic spaces, causing wood rot or mold.

Continuous eave and roof ridge vents will create natural air flow through the attic. Air enters through the eave vents, and moves out through the ridge vents. As heated air rises, it ventilates the attic.

Lighter colored roof materials absorb less heat.

Reflective heat barriers on the underside of the roof deck help to reduce heat gain.

High levels of insulation in attics and exterior walls is crucial for comfortable indoor temperature in all climates.

Some research is being done on building sealed, highly insulated attics.

3) Optimize your heat and AC systems.

An oversized system will cool too quickly, and leave the room clammy. Smaller systems run long enough reach the desired temperature, and, at the same time, clear the air of humidity.

A smaller system lasts longer, does not cycle on and off frequently, and costs less to purchase.

Check for leaks in duct work joints, and around windows, doors, attic stairs, exhaust pipes, recessed lights, and electric outlets. Ongoing maintenance of central air systems is necessary to prevent air loss.

Use programmable thermostats to regulate your energy usage.

Use Pleated-Media Filters in AC return-air grills. This filter removes particles as small as mold spores from the air that is drawn back into the AC blower, keeping coils cleaner and improving the air quality in your home.

Heat pumps on electric furnaces reduce energy use by drawing heat from outside air, using the same technology that air conditioners use to remove heat from indoor air.

Check with your utility provider for free diagnostic testing and rebates for high efficiency AC systems, insulation, solar screens, and weather-stripping.

4) Reduce water needs.

Native landscaping that is suited to the rainfall in your area is fundamental to building green.

Keep as much native growth on your lot as possible.

Water pervious materials such as crushed granite or open paving blocks allow water to percolate into the ground.

Rainwater catchment systems use gutters and barrels to catch and store water that falls on roofs.

Front loading washing machines use less energy and water. Some dishwashers use less water and have no-heat drying. Check water and energy usage before buying appliances.

Low flow toilets and shower heads reduce water usage.

Reduce water and fertilizer needs by re-cycling yard waste and leaves for use as mulch.

5) Use renewable or recycled materials.

Consider decks made of waste wood and plastic, such as Trex or other brands.

Medium density fiberboard (MDF), a wood product used for interior trim and doors, does not contain formaldehyde.

Fiber-Cement siding, trim, and pipe materials (Hardie Board) are very durable, rot resistant, and fire retardant.

Use locally produced, and easily renewed, materials when possible.

Consider alternative building materials, such as rammed earth, straw bale or insulated concrete panels.

Concrete floors utilize the foundation material as finish floor, saving materials and labor.

Recycled wood floors are a very attractive re-use of materials.

Bamboo floors are made from a rapidly renewable source – bamboo is a grass that can grow several feet per day.

Hard surface floors do not hold dust, molds, and allergens, and are very durable.

Use materials with recycled content when possible, such as cellulose insulation, Thermo-ply, and lumber composites.

Plan for a place to re-cycle household trash, such as a storage bin in the kitchen, and holding bin in the garage.

6) Safeguard your site.

Trees, vegetation and bird habitat on the site should be protected during the construction.

Native trees, grasses, rock outcroppings and natural drainage can be made a part of your building and landscaping design.

Reduce the impact to the building site as much as possible.

Make sure construction waste is properly disposed of, especially paints and solvents. Do not allow them to be buried on the site.

7) Use safe materials.

Use products that are biodegradable, non toxic, water based, and cold water compatible.

Avoid products that contain dyes, ozone depleting chemicals, heavy metals, formaldehyde, or known carcinogens.

Avoid solvent based finishes, particleboard, adhesives, some carpets, and other products that release volatile chemicals into the air.

Look for green rated labels on carpets and other products.

Remove old-style pressure treated wood when possible, especially in play structures.

Green building is an approach to design and construction that respects the environment and conserves resources. It is a common sense approach that is available to all home owners. Green building techniques create a more cost effective, enjoyable and sustainable home to live in.

About the Author

Roselind Hejl is a Realtor with Coldwell Banker United in Austin, Texas. Her website - http://www.weloveaustin.com - offers homes for sale, market trends, buyer and seller guides.
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