tag:blogger.com,1999:blog-30674545295226011282024-03-20T01:12:37.134+13:00Fuel from waste oil and plastic DIY OrionMake diesel, kerosene, petrol, etc at home from waste hydrocarbon. Content will be updated, please check back soon. Thanks.Excaliburhttp://www.blogger.com/profile/10595000113080348084noreply@blogger.comBlogger21125tag:blogger.com,1999:blog-3067454529522601128.post-13446937417687885692015-05-12T19:34:00.000+12:002015-05-12T19:34:30.182+12:00Test run of the newly refitted OrionI ran the Orion diesel making machine after a lengthy refitting. A number of refinements were commissioned including brick refractory, revised retort weighing mechanism, I.D. (induced draft)fan and preheater.<br />
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240 liters of .848SG was made during actual production time of about 8 hours. Feedstock was a variety of waste mineral oils.<br />
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There was number of problems: <br />
The reflux vessel had some leaks which were fixed. <br />
Extra retort insulation was added and it was noted there was 60+ degrees of difference between lower and upper TC sensor probes. <br />
The feed pump struggled, the cause discovered the following day as a kinked hose.<br />
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Improved feedstock quality put an end to previous boil-over episodes. Throughout the 8 hour production, amber diesel never ceased to flow through the sight glass, albeit at varying rate. <br />
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The run highlighted some useful information.<br />
High flame temperature was needed so more insulation is required on the retort vessel.<br />
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The preheater can get really hot with temperature of 400°C+ noted. More insulation would benefit efficiency. Hot feedstock was optionally be piped back to the in-tank allowing heating of the vessel and separation of suspended water.<br />
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The production rate at low retort levels has some good things going for it. It requires less heat to evaporate and runs at a good speed. Sadly the failing feedstock pump didn't allow proper testing.<br />
Next run I'll start with little or no feedstock in the retort then begin to add enough to suit the applied temperature. Ultimately I hope to adjust feed flow to raise/lower retort target temperature.<br />
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The retort weighing device worked much better than previous iterations. With reasonable accuracy I could determine empty-to-full status. Later refinements could include a strain gauge with LCD readout, alarms and programmed automation of pumps and valves. <br />
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It appears that the refractory bricks require a lot of warming up but they are impervious to direct flame heat. In addition these dense bricks are heat stores/conductors but poor insulators.<br />
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Various pipe threads throughout the plant (except retort/reflux zone) were sealed with automotive exhaust cement. This worked well so I'll be carefully evaluating.<br />
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Pics of the various modifications to follow, see appropriate pages of this blog..<br />
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Upgrades before next run could include: heat recovery, insulation, preheater. Also I'm pondering on making an operator checklist to ensure vital components like valves are correctly set.Excaliburhttp://www.blogger.com/profile/10595000113080348084noreply@blogger.com5tag:blogger.com,1999:blog-3067454529522601128.post-92092101047372721952015-03-22T22:56:00.000+13:002015-03-25T16:33:29.904+13:00Major refit It was back to the drawing board with a major revision after the refractory failure. Refractory kiln bricks and calcium aluminate castable cement for the difficult areas was chosen. The bricks were cut to shape then dry stacked so they hold each other in place. The flame inlet is round 3.5 inch heavy gauge steel pipe with a coolant jacket. Castable cement was used to form and adapt the difficult shapes.<br />
The turk burner head has been moved away a few hundred millimeters. Some loose bricks were stacked on the firebox floor to create a torturous flame path. The object is to soften the ferocity of the flame so making the retort temperature more stable. A test run firing without the retort vessel in place looked great. See pic.<br />
As I write the retort is in position but there is much work to do. The firebox upper needs fabricating. The reflux needs packing/trays. The new retort weighing mechanism needs testing. The injector pump drive motor requires bearings. The induced daft fan needs a cover. Revisions to the preheater plumbing. Instrumentation cabling/ adapting.<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgq3Nj4DH_f7m3hJH2QU5lTwwG0DQLRLMTZetSm91oxk4LH9-NI7tImRll7Rc06wNgoTXKgX_cNU38G8deqJSX1tcmQclcOvuzL89bHLI-pVqRj7zznBlY6r6Pxg9rBXW78EJeE-MLLb6I/s1600/566556200+006.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgq3Nj4DH_f7m3hJH2QU5lTwwG0DQLRLMTZetSm91oxk4LH9-NI7tImRll7Rc06wNgoTXKgX_cNU38G8deqJSX1tcmQclcOvuzL89bHLI-pVqRj7zznBlY6r6Pxg9rBXW78EJeE-MLLb6I/s1600/566556200+006.JPG" height="240" width="320" /></a></div>
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Test firing the 'labyrinth' designed to soften the harshness of flame</div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh2cf_SSnRQRnoyKstvztK_s1aBe0Y-avvlchSAEEVdhf5_MfdcuqbMR9Xj4TbHqzzkSn5Rewll_ffA1DF9oobUnVvqWBRYs_cQTFgWQ8dLALXnQfoKQTozyL9aKVvFQhMVzYgIubkSglc/s1600/566556200+001.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh2cf_SSnRQRnoyKstvztK_s1aBe0Y-avvlchSAEEVdhf5_MfdcuqbMR9Xj4TbHqzzkSn5Rewll_ffA1DF9oobUnVvqWBRYs_cQTFgWQ8dLALXnQfoKQTozyL9aKVvFQhMVzYgIubkSglc/s1600/566556200+001.JPG" height="240" width="320" /></a></div>
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Firebox brick wedge structure</div>
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Turk burner head in new position slightly further away from retort.</div>
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Excaliburhttp://www.blogger.com/profile/10595000113080348084noreply@blogger.com0tag:blogger.com,1999:blog-3067454529522601128.post-5474817534360983292014-09-25T23:06:00.001+12:002014-09-25T23:06:08.112+12:00Setbacks to sortThe retort suffered decay of the heat ducting. It appears as though proper refractory is needed to properly fix the issue. The retort vessel itself appears unaffected. Currently I'm pondering over the future of the plant. One option is to accelerate plans to develop a flash evaporator for converting WMO to diesel. Initial test of crude prototypes were encouraging but far from economic as yet.<br />
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The fuel from the retort appears to be forming gum resin. This has been discovered in a product pump, seizing it. Also in a vehicles' filter. According to research, oxidization can create gum so the hunt is on for a remedy.<br />
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Vehicle filter with gum resin fall out.</div>
Excaliburhttp://www.blogger.com/profile/10595000113080348084noreply@blogger.com2tag:blogger.com,1999:blog-3067454529522601128.post-69991760962511437792014-08-07T21:59:00.000+12:002016-01-08T18:35:23.822+13:00New parts for OrionAmongst new parts for the Orion retort trialed recently was an extended thermocouple retort probe, Sestos temperature controller and a solenoid for burner control.<br />
The probe showed there is 10°C - 30°C difference between the upper and lower parts of the retort.<br />
The thermocouple LCD's were re-housed in a cabinet recycled from an old PC chassis. <br />
Preheating of the feedstock was by 230v recycled water-heater which was targeting 100°C. Several feedstock pumping speeds were tested. These were obtained by changing the motor pulley sizing.<br />
Boil-over episodes continue to frustrate the distillation process so yet another rethink is underway to solve this issue. The feedstock appears to be a factor causing the boil over and this why the yield was down to 150 liters produced.<br />
One remarkable thing realized was that ambient temperature has a significant effect on the amount of heat that needs to be applied. Midwinter with the chill factor after dark really showed this phenomena up.<br />
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Excaliburhttp://www.blogger.com/profile/10595000113080348084noreply@blogger.com0tag:blogger.com,1999:blog-3067454529522601128.post-36708040096625993652014-06-30T00:40:00.000+12:002014-06-30T00:40:22.250+12:00Another 250 ~ 260 liters processed .845 SGA run making diesel weight fuel of .845 Specific Gravity was completed at the weekend. There was a number of new parts to test including extra retort insulation, scale balance for weighing retort, additional temperature gauges, revised preheater iteration and turk injector pump nozzle tweaks.<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjDuVtzTUHPER5v4mYNYJvTWXW1HdyC0ZmAZeCGkinNzGLkJ-_PDAlw1hNaEtq7l5tibQJyoQsApXgoNkGcm353gIQcV-x1q4FcSQYbFSVqx8OtqVsJgCdspxWqgb-RFBpUdB931Quz-fA/s1600/1125545+002.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjDuVtzTUHPER5v4mYNYJvTWXW1HdyC0ZmAZeCGkinNzGLkJ-_PDAlw1hNaEtq7l5tibQJyoQsApXgoNkGcm353gIQcV-x1q4FcSQYbFSVqx8OtqVsJgCdspxWqgb-RFBpUdB931Quz-fA/s1600/1125545+002.JPG" height="240" width="320" /></a></div>
Some new thermocouples were added. The 'Exhaust' recorded up 250°C so will be heat source of the newly proposed preheater heat-exchanger. 'Oil-in' is the temperature at which preheated oil feedstock enters the secondary heating stage, a pipe-in-pipe heat exchanger. The 'Burner' shows the current flame temperature as it exits the turk-burner-head.<br />
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Here the sight glass was showing water droplets. I believe the oil feedstock was wet with a suspended water content. This may have been responsible for the boil-over problems experienced.</div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgKdAw-trHuos6iBtZKX6fumKq2rGpd5P7dAHqjhvMx3C0v9Zq9EGIeHVmhWSWLJ7vHl27K9Y7gwiyFgTx9lx_3TDCD_R9metxkLLhNbRuMigdhmdtlhvee3s_VwHDb2k_o6aT60bESZ-M/s1600/1125545+007.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgKdAw-trHuos6iBtZKX6fumKq2rGpd5P7dAHqjhvMx3C0v9Zq9EGIeHVmhWSWLJ7vHl27K9Y7gwiyFgTx9lx_3TDCD_R9metxkLLhNbRuMigdhmdtlhvee3s_VwHDb2k_o6aT60bESZ-M/s1600/1125545+007.JPG" height="240" width="320" /></a></div>
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This is the feedstock infeed pump which is a simple gear pump commonly used on boats. In order to obtain the speed I wanted, I had to gear it down considerably. I'm far from convinced that this pump is delivering the quantity at which it was tested. It turns quite slow and has to pump 100°C oil so may be suffering because of it.</div>
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This is the reduction gearing made from a bicycle wheel rim, which drives a set of bicycle sprockets giving the required deep reduction. Theory says the current range of spare motor pulleys allow feedstock rates between 30 and 45 liters per hour.</div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjBe0RIOxf9SB5JAvWGQ26TOnldMZNR5HHqrvf7asBvmx_83UuhfQnitKO7XHFTt6EyP214qdY44EGh2UHzICnjqQmB5WZmn-xDTsaXPyVnyFUj6PQZS61VyFZl3AUr9sgRByTdloUZmZ4/s1600/balance+scale.png" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjBe0RIOxf9SB5JAvWGQ26TOnldMZNR5HHqrvf7asBvmx_83UuhfQnitKO7XHFTt6EyP214qdY44EGh2UHzICnjqQmB5WZmn-xDTsaXPyVnyFUj6PQZS61VyFZl3AUr9sgRByTdloUZmZ4/s1600/balance+scale.png" height="180" width="320" /></a></div>
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The approx. 40kg of balance scale weights used to determine how much feedstock is inside the 47 liter retort. This is a great help for the operator when using a constant or batch feed pump to deliver fresh feedstock. The weights are recycled cast iron pulleys and flywheels.</div>
Excaliburhttp://www.blogger.com/profile/10595000113080348084noreply@blogger.com0tag:blogger.com,1999:blog-3067454529522601128.post-53185435765609085982014-06-05T19:58:00.001+12:002014-06-05T19:58:07.184+12:00Preheater test runI completed a test run with a preheater designed to raise the temperature of the oil feedstock.<br />
About 180Liters of diesel was made during the day though numerous problems prevented a better result. The feedstock feedpump failed to deliver, the preheater boiled over, the retort over filled were amongst problems encountered.<br />
It's becoming clear that the feedpump should have been mounted lower with respect to the preheater.<br />
At times the pump could not pick up the oil. High oil temperature would have thinned the viscosity and in addition the pump rpm was too slow to make the system reliable.<br />
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Also a reliable method of accurately determining retort level urgently needs to be found. This problem has been particularly troublesome and frustrating. The liters per hour could increase by a good margin if this was sorted. In addition, heating energy could be saved.<br />
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The bigger gasjar functioned as expected. It is over double capacity.<br />
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I have about 180 liters of diesel which is being progressively fed into the up-flow settling tanks.<br />
Therefore I have 3 ~ 4 weeks of fuel. By then I want to be ready with the next round of modifications.<br />
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Thanks for viewing my blogExcaliburhttp://www.blogger.com/profile/10595000113080348084noreply@blogger.com0tag:blogger.com,1999:blog-3067454529522601128.post-30453166891085790612014-04-23T23:00:00.000+12:002014-04-23T23:00:37.590+12:00265 liters diesel at .848 SG265 liters was the yield from 13.5 hours of continuous run time for the Orion retort refinery. On a 8°C early morning the heat was started at 7am and concluding after dark at 8:30pm<br />
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A 574 liter diesel receiver reservoir was prepared and fitted. Freshly painted in green it was fitted with insulation with the holding temperature aimed at 80 - 100°C. The target was slightly short with max temperature eclipsing only 70°C.<br />
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The gasjar overflowed several times so this will be one planned upgrade. It needs enlarging and the contents needs to be "visible-at-a-glance". In addition I want to move it outside and away from the retort shelter.<br />
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It is becoming more obvious why the retort will only make 20 liters per hour as a maximum ceiling rate. The ingoing feedstock cools the retort too much resulting in down time when production slows to a trickle. <br />
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The newest device, a retort level indicator hasn't worked as well as hoped, so a rethink of its' capability is underway. Knowing where the level is critical for efficient running as too low makes for slow production while too high invites boil-over. (See retort page for details.)<br />
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Hydraulic lines replaced old oil feed and heat exchanger hoses. These worked well. A plugged strainer slowed production for a short time till the fault was located. A larger replacement is planned.<br />
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The diesels' specific gravity of .848 SG was in line with the target. Picture is of the diesel with the hydrometer floating in a recycled fruit juice container. The diesel is quite dark in color though if occasional boil-over events can be eliminated, this would be beneficial. Other batches have had similar color though perform well after filtering.<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg1HlbO1qCu451f5XEMfIidonlKKa7g435AgkMbPSuw167EK8EQTJbqZ1UST9x1L9zvlUNYyMXVCNysC1SADnoR53OlOjWSAd46vySMeqh7c9ZjsfY-QBBOvT63aNr6WHNbQE2wLh_2s6U/s1600/dwewgdfg+004.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg1HlbO1qCu451f5XEMfIidonlKKa7g435AgkMbPSuw167EK8EQTJbqZ1UST9x1L9zvlUNYyMXVCNysC1SADnoR53OlOjWSAd46vySMeqh7c9ZjsfY-QBBOvT63aNr6WHNbQE2wLh_2s6U/s1600/dwewgdfg+004.JPG" height="240" width="320" /></a></div>
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Planned upgrades next are revised and enlarged gasjar, burner door seal, anti-boil-over device, additional instrumentation and improved preheating of feedstock.</div>
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The next run will be in relatively quick succession as extra fuel is required for the new diesel settling upflow tanks. This setup needs diesel to be left for a month+ to release sub micron particles by gravity. </div>
Excaliburhttp://www.blogger.com/profile/10595000113080348084noreply@blogger.com0tag:blogger.com,1999:blog-3067454529522601128.post-29836510062846385852014-04-01T00:59:00.001+13:002014-04-08T12:05:34.920+12:00Orion Schematic design<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjldHZO5V4PVJeZNq8MWIS76a3MVCjXb8ZRwtS_lypYPsjN-ir2DVf3l3L5MC8r4vZBLknFPB2Jn84lae1eDy1MZOPJon8jGpJQnGJlwQagGf8gBzgyHRWRG31ft1X2jtCORdjOU0TLTJ8/s1600/orion6.91.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjldHZO5V4PVJeZNq8MWIS76a3MVCjXb8ZRwtS_lypYPsjN-ir2DVf3l3L5MC8r4vZBLknFPB2Jn84lae1eDy1MZOPJon8jGpJQnGJlwQagGf8gBzgyHRWRG31ft1X2jtCORdjOU0TLTJ8/s1600/orion6.91.jpg" height="452" width="640" /></a></div>
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1April2014 Schematic design showing basic layout. Made using Open Office Draw.<br />
Please browse this blog for the dedicated <u>schematic diagram library page</u> with more schematicsExcaliburhttp://www.blogger.com/profile/10595000113080348084noreply@blogger.com5tag:blogger.com,1999:blog-3067454529522601128.post-41620423919334577552014-02-01T11:05:00.001+13:002014-02-03T17:20:26.065+13:00Another run making dieselMake was 185 liters diesel and 5 liters petrol.Pic shows reflux and retort temperatures using 12v LCD display from thermocouple signal<br />
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The condenser array temperature readings using 12v powered gauges which are probably PT100.<br />
They read to 150*C max. I aim to have the diesel reading higher than the shown reading to drive of volatile fractions down to the petrol condenser. Because I don't require petrol the shown temperature of little more than ambient may have helped power the turk burner with gases.<br />
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The turk was able to be powered mainly by gases once it was up to temperature. Continuous run in excess of 2 hours gas was nice.</div>
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Full speed for the diesel flow was recorded at 1 liter per minute but that rate couldn't be maintained as any incoming feedstock cooled the retort.</div>
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<object width="320" height="266" class="BLOGGER-youtube-video" classid="clsid:D27CDB6E-AE6D-11cf-96B8-444553540000" codebase="http://download.macromedia.com/pub/shockwave/cabs/flash/swflash.cab#version=6,0,40,0" data-thumbnail-src="https://ytimg.googleusercontent.com/vi/50D_P3LUFYE/0.jpg"><param name="movie" value="https://www.youtube.com/v/50D_P3LUFYE?version=3&f=user_uploads&c=google-webdrive-0&app=youtube_gdata" /><param name="bgcolor" value="#FFFFFF" /><param name="allowFullScreen" value="true" /><embed width="320" height="266" src="https://www.youtube.com/v/50D_P3LUFYE?version=3&f=user_uploads&c=google-webdrive-0&app=youtube_gdata" type="application/x-shockwave-flash" allowfullscreen="true"></embed></object></div>
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Full story shortly as I find time...</div>
Excaliburhttp://www.blogger.com/profile/10595000113080348084noreply@blogger.com1tag:blogger.com,1999:blog-3067454529522601128.post-62972517357366702762013-12-22T18:37:00.000+13:002016-01-04T13:01:05.516+13:00Orion,180 liters diesel distilled in 9hours, record run<div class="separator" style="clear: both; text-align: center;">
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I made a good step forward with efficiency with the latest changes to the Orion retort. The video shows selected footage of diesel production. Nine liters of diesel was used to fire the turk burner head, plus retort generated gases were used as well. At times the gases were enough while other times the turk was used to supplement. The video shows the turk injector pump running, sounding like a tractor while the second part of the clip displays the gases alone doing the heating. The faint eerie howl of the forced draft fan can be heard.<br />
More soon. thanks.Excaliburhttp://www.blogger.com/profile/10595000113080348084noreply@blogger.com1tag:blogger.com,1999:blog-3067454529522601128.post-43556773991791595352013-12-04T20:40:00.000+13:002014-01-26T14:06:51.994+13:00Readying for the next run with modifications<h4>
Retort cleanout and preparation</h4>
Retort clean out after about 24hr+ of use. I was surprised at how little build there was and that there was no feedstock left. I'd snipped the run early, while still making fuel so I think the evaporation continued for some time.<br />
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This is the lid which was wet with soft blobs and a strange greenish tinge to the port that leads to the reflux chamber . There was no apparent leakage at taper seal. The stork at lower right is the thermocouple adapter.<br />
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This pic shows the retort bottom looking down from the top flange, 1.5m away. The carbon had formed a crust at the bottom in a layer which was crazy cracked and about 20mm+ thick. The wall was fairly clean.<br />
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Close-up of the carbon after breaking up and removing. It was dry and biscuit like.<br />
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The scoop I made to clean the carbon from 1.5m below. A slightly more robust version of this will be made for next time.<br />
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The lid of the reflux chamber with copper gasket as removed. The seal was good and the carbon thin and flaky.<br />
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This pic looks at the reflux chamber from above. I had swarf and a perforated grate, I'll be leaving these out for next assembly. Note the flakes of carbon still attached to the rim at the 2 o'clock position. <br />
26Jan2014 Update: Leaving out the swarf packing didn't see any benefit so I'm refitting as of next run.<br />
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<h4>
Turk Burner head driven by I.P.</h4>
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This is the latest iteration of my turk which uses preheated air. It is fed by a VE rotary injector pump and 240v motor. More info: Turk burner head page.</div>
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Counter-current preheated feedstock-oil feed</h4>
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Details shortly</div>
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Excaliburhttp://www.blogger.com/profile/10595000113080348084noreply@blogger.com0tag:blogger.com,1999:blog-3067454529522601128.post-66302195558993563512013-10-25T18:21:00.000+13:002013-11-03T21:26:45.151+13:00Mk6 Turk-Retort test runThe new retort produced 130 liters (US34gallon/UK28gallon) in testing 24October2013. The feedstock was a mixture of waste mineral oils. Run time was 13 hours. There were numerous problems but I have a clear path for development. A much higher yield than the 10 liters per hour should easily be attainable. The computer shown in the video shows the graphic interface for the PID monitoring and adjustment which controls the heating. The viewing port is made in the workshop and uses 16mm borosilicate (Pyrex) glass. It provides a fantastic view of the drip rate.<br />
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Fuel sample</div>
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Excaliburhttp://www.blogger.com/profile/10595000113080348084noreply@blogger.com0tag:blogger.com,1999:blog-3067454529522601128.post-39138938458911937422013-09-23T19:04:00.000+12:002013-10-20T18:53:24.325+13:00Success !!!<div class="separator" style="clear: both; text-align: center;">
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23Sept2013 Here is what the miniature refinery site looks like at close to the point of completion. After numerous delays, the testing will commence shortly.<br />
With a few little jobs to do, I'll do a maiden run as soon as the basics are in place. Naturally there'll be things to tweak, improve and modify. There's 20liters of waste oil in the retort ready for cracking.<br />
Probably the continuous feed pump and the centrifuge will come later, once the retort basics are sorted.<br />
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24Sept2013<br />
The heat exchanger is ready to pick up tomorrow!<br />
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3Oct2013<br />
I processed about 5 - 10liters today to give the retort a trial. Getting the temperature up was slow but once gas was being produced, it lifted much quicker. Several things need tweaking and sorting.<br />
The Arduino required reset a few times plus the PC locked up. Initial firing set up was needs revision.<br />
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A more stable power supply for Arduino, servo and PC.<br />
A dedicated water feed for the condenser.<br />
Revised plumbing to the sight glass.<br />
Various turk air/fuel inlet remedies.<br />
Fire hose needs mounting and plumbing.<br />
Replacement thermostat for the bubbler.<br />
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4Oct2013 I got most of the list done today so am going to rerun tomorrow. The turk inlet gets a major work over. Pics up shortly on the appropriate page.<br />
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7Oct2013 The retort has made about 80 liters in a series of test runs. The reflux seemed to benefit from lagging to keep the heat up to my target of 300*C. The PC is still locking up but I discovered the likely reason to be Java. Xp task manager reports it using 98% cpu. Heat management was by manual control. The sight glass viewing port is a Godsend. The bubbler view ports clouded over to very opaque. I learnt a lot about retort behavior. Next trials will be in a couple of weeks' time.<br />
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20Oct2013 Upgrades in progress<br />
1/. Feedstock and diesel vessels with marked increments for quantity.<br />
2/. Heated fuel feed for the turk.<br />
3/. Solve the software issues re PID servo.<br />
4/. Bubbler sight glass.<br />
5/. Repositioning the gas feed for the turk.Excaliburhttp://www.blogger.com/profile/10595000113080348084noreply@blogger.com0tag:blogger.com,1999:blog-3067454529522601128.post-5180971954885972932013-08-08T12:31:00.001+12:002013-09-15T21:16:56.866+12:00Steady progress!<div class="separator" style="clear: both; text-align: center;">
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Progress as of 8Aug2013. To the left is the retort which black reflux tower on top.<br />
Red vessel is bubbler with yellow draw-back arrestor above. Drum to the right is the diesel condenser vessel. Check back soon for commissioning and testing results.<br />
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13Aug2013<br />
Some of the 200L drums of oil waiting to be refined into diesel:<br />
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23Aug2013 I've made a list of things to complete before I can test. I focus on the job much better when there is a list. There are 46 items. Today I finished 8 of those tasks. I'm getting excited! My goal to test before month end appears achievable.</div>
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25Aug2013 The list has 12 items completed now but it grew to 50 overall. Of course some of the things are partly completed even now. Naturally, I did the easy things first LOL.</div>
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A week to go till deadline. I can see an over-run looming. I have extra work landed on my plate plus Thursday brings an out-of-town pick up to do.</div>
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7Sept2013 Hopefully testing can begin by next weekend. There are some jobs to do, namely the heat exchanger and the bubbler sight glass.</div>
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15Sept2013. Am just waiting on heat exchanger welding, plumbing parts and then the final assembly.</div>
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See the blog pages for in depth look at the parts. Updated!<br />
<br />Excaliburhttp://www.blogger.com/profile/10595000113080348084noreply@blogger.com0tag:blogger.com,1999:blog-3067454529522601128.post-31475467458271724972013-06-07T14:08:00.000+12:002013-07-19T17:10:00.466+12:00Shed construction for the new mk6 turk-retortI cleared an area of flax for sheltering the new retort. The roofing is 6m span and made from a recycled carport.<br />
I have mains power just 3m away with 2 water pumps, 1000L tank plus a high powered ground water bore/pump used for irrigation. So just thinking safety here and planning to control any fire/emergency. <br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgfe49Cl9W1w5M6FXuERzl9DnZvve3qoeiXAd_5hKiJgpFX49SJ5LTt3uSH7-6nAUSVyQiq1ugJOM0pPOPvf5jdt4AMEHW4duvjbdJKoMdxX8r0H6yBonCzwH79NScfFuXWIFqbc3NFCDI/s1600/hr56765+003.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="480" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgfe49Cl9W1w5M6FXuERzl9DnZvve3qoeiXAd_5hKiJgpFX49SJ5LTt3uSH7-6nAUSVyQiq1ugJOM0pPOPvf5jdt4AMEHW4duvjbdJKoMdxX8r0H6yBonCzwH79NScfFuXWIFqbc3NFCDI/s640/hr56765+003.JPG" width="640" /></a></div>
The structures' steel work will form the frame for mounting the various parts. <br />
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<strong>"Work in Progress"...</strong><br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgU9zNJls97LbqgkGHy-6OH8NPH0P_2QMk7V9ddlaciHAS-QgbFkPfas1HmAr-wBLQ3ICo5dCJJa6cVrpYbfIdvSphZpyB3vBUGPEd1jyWqU32F9j_PmnuvGgXxgS8h9wUYQa7glC0sg5E/s1600/df4644k+001.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="480" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgU9zNJls97LbqgkGHy-6OH8NPH0P_2QMk7V9ddlaciHAS-QgbFkPfas1HmAr-wBLQ3ICo5dCJJa6cVrpYbfIdvSphZpyB3vBUGPEd1jyWqU32F9j_PmnuvGgXxgS8h9wUYQa7glC0sg5E/s640/df4644k+001.JPG" width="640" /></a></div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhp1IP2PX2YR2ovpbS3WmB8cwIYQaH4iFRWzK-_xNx7KLb6SB2emNKp5y6joEksxL0FZO1ggUhTEIIZ3rjxQqO69v5PoUUv7i0Cv3K873jn2JzjtHdI5pnY0vjhe7Br-I9z2k_fmyT6-sA/s1600/ftdf657567+008x.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhp1IP2PX2YR2ovpbS3WmB8cwIYQaH4iFRWzK-_xNx7KLb6SB2emNKp5y6joEksxL0FZO1ggUhTEIIZ3rjxQqO69v5PoUUv7i0Cv3K873jn2JzjtHdI5pnY0vjhe7Br-I9z2k_fmyT6-sA/s320/ftdf657567+008x.jpg" width="240" /></a></div>
I got the 3mm turk outer skin fully welded with the inlet and exhaust oriented at 180degrees. A chain block is mounted above to lift it. Next comes the insulation and outer cladding....<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj-7epyJoWrKtVG_mSxRC7xljr8xkN7cfpuwvVx7gsI9yQLjuzS3duQbLgK9_M3AT2qwTC0UXUJ5CXecOIC_P5TclXmrU3ReyIteljka8GObxc4xutM_tRqx8Vmsp12REbElEjLEqT7jvY/s1600/654ioio+002.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj-7epyJoWrKtVG_mSxRC7xljr8xkN7cfpuwvVx7gsI9yQLjuzS3duQbLgK9_M3AT2qwTC0UXUJ5CXecOIC_P5TclXmrU3ReyIteljka8GObxc4xutM_tRqx8Vmsp12REbElEjLEqT7jvY/s320/654ioio+002.JPG" width="240" /></a></div>
The retort is lowered into the lower section of cladding. It was leveled and centered. The gap of about 125mm is for the vermiculite insulation.Excaliburhttp://www.blogger.com/profile/10595000113080348084noreply@blogger.com0tag:blogger.com,1999:blog-3067454529522601128.post-47844406049346666902013-02-04T21:12:00.000+13:002013-02-04T21:12:44.597+13:00Turk retort mods shakedownToday I ran the tuk-retort with the modifications of injector pump feed for the turk. This was a big step forward in control of the heat. I processed 20Liters and yielded over 19L. The non-condensables were fed back to the turk and burnt as heat. There is still work to do to sort out the condenser temperatures as I want to use more of the gases from the retort as heat in the turk.<br />
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Part 1</div>
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Part 2</div>
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Part 3</div>
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In addition to the water cooling, I fitted an extra fan for the 1st condenser and held its' temperature 80C - 120C. Most of the fuel was diesel with reflux at 220C .</div>
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The turk has a tractor like sound with the diesel firing and the non condensable gases howl in the turk.</div>
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Excaliburhttp://www.blogger.com/profile/10595000113080348084noreply@blogger.com0tag:blogger.com,1999:blog-3067454529522601128.post-45256722238862060372013-01-30T22:32:00.000+13:002013-02-01T22:03:29.599+13:00Turk-retort revised heating system upgradeHere are the parts of the Turk-retort during the revised heating upgrade.<br />
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Left: This is the underskin lined with kaowool. <br />
Lower left: this large disk with the keyhole shape is the upper cover.<br />
Back center: turk inner skin.<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhmjutW6ktjO_03p0ObFBxIyeJt3xxNnxi109VRzbx3gTipEruI_UosDAQBi_V6x6-dKPF5q93nNHCvTdC9YUauY2ppxlWp-n0u4aA3QUVPvD8Bllg0C7M4XaO6DMTRFMgP6UUWgnBBV0Q/s1600/mh+001.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="480" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhmjutW6ktjO_03p0ObFBxIyeJt3xxNnxi109VRzbx3gTipEruI_UosDAQBi_V6x6-dKPF5q93nNHCvTdC9YUauY2ppxlWp-n0u4aA3QUVPvD8Bllg0C7M4XaO6DMTRFMgP6UUWgnBBV0Q/s640/mh+001.JPG" width="640" /></a></div>
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Insides of the Turk: Two fuel injector ports are visible inside and two visible outside. These provide the fuel for the 400C+ heat.<br />
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The long 3inch tube is the air inlet which is forced fed by 3 stage fan.<br />
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Vessel with pressure guage is the reflux. Retort vessel is to the far right. The yellow cannister is a flame trap.<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjCoQ2K23T-Tm_j0FCVGmgq9dG_IC1tNUq3J2pkv3ZNyiPUI84QdYOkcFO_AKok6oaKyNCScs7G0x45rTsO-EwomUKd_OAYmO8UFGQ82_Ow0LgqqNesHrC43oxN1CnrwJ_sVH_R6_GLcOo/s1600/mh+006.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="480" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjCoQ2K23T-Tm_j0FCVGmgq9dG_IC1tNUq3J2pkv3ZNyiPUI84QdYOkcFO_AKok6oaKyNCScs7G0x45rTsO-EwomUKd_OAYmO8UFGQ82_Ow0LgqqNesHrC43oxN1CnrwJ_sVH_R6_GLcOo/s640/mh+006.JPG" width="640" /></a></div>
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Not pictured is the outer skin and the rest of the kaowool. Thanks for viewing my blog.Excaliburhttp://www.blogger.com/profile/10595000113080348084noreply@blogger.com0tag:blogger.com,1999:blog-3067454529522601128.post-37815358414909379252013-01-26T19:45:00.001+13:002013-01-26T19:45:49.197+13:00Turk mods for better heat control<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjrMD9fhT3QN9hxl1Y1Tp3EasJYiEr_tYglL3IgU8sbD9uOQviDZ-SDDWD2eGSyXBpZKXE1dor84BVvUdYeLyGbzpNE_o06mVi_bthsBcII_fku2oN1ek_-BmyVRthASzcNthSQdJzu2Yc/s1600/turk+006.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="480" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjrMD9fhT3QN9hxl1Y1Tp3EasJYiEr_tYglL3IgU8sbD9uOQviDZ-SDDWD2eGSyXBpZKXE1dor84BVvUdYeLyGbzpNE_o06mVi_bthsBcII_fku2oN1ek_-BmyVRthASzcNthSQdJzu2Yc/s640/turk+006.JPG" width="640" /></a></div>
Here are the Toyota injectors which will serve for the turk fuel control. The idea is that the fuel can be positively controlled and therefore the heat can be held within a tight range. The pulley on the IP will allow a vee belt drive from an electric motor. The ratio is about 5:1, the motor does 1440rpm so the IP will turn at 288rpm.<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj2V04urbFKsMOLoc0A58fUoFJ1Hab-vJ7IiyljcYIwCrMfUm0QxPWVd59lWj6brxAs8q6-VjFA5MioBYMxwAHS_aZL90rQVhZhoEJiuwt9oOFrEDwwrN3vSBxSHqvzvJY99rSaOD2yzaU/s1600/ip+001.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="480" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj2V04urbFKsMOLoc0A58fUoFJ1Hab-vJ7IiyljcYIwCrMfUm0QxPWVd59lWj6brxAs8q6-VjFA5MioBYMxwAHS_aZL90rQVhZhoEJiuwt9oOFrEDwwrN3vSBxSHqvzvJY99rSaOD2yzaU/s640/ip+001.JPG" width="640" /></a></div>
This a side view of the Injector Pump (IP) as found. Some of the lines will require increasing in length to reach the nozzle position which are planned at 90' apart. This is purely experimental and unproven theory but the hope is to gain better control over the temperature to avoid the extremes of boil-over and inefficient evaporation from too low temperature.Excaliburhttp://www.blogger.com/profile/10595000113080348084noreply@blogger.com0tag:blogger.com,1999:blog-3067454529522601128.post-13832384316859331362013-01-01T16:20:00.001+13:002013-01-26T19:48:34.722+13:00Youtube videos, making homemade diesel and petrolThis is the 1st part in a 7 part series of the hydrocarbon cracking DIY.<br />
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See the other 6 parts on my Youtube channel.<br />
<a href="http://www.youtube.com/user/SmokeOnTheQuarter">SmokeOnTheQuarter</a>Excaliburhttp://www.blogger.com/profile/10595000113080348084noreply@blogger.com0tag:blogger.com,1999:blog-3067454529522601128.post-78686581822724186222012-10-06T20:19:00.000+13:002013-03-22T10:45:28.662+13:00<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEie_5i4Bkp8AKdcQCEmvcfGuTVqtaSGGfd6s0Ig0HhmgVWl3XPI96OAmsajxWw-mfMwjPfwYJK3ckSiCxzWYPgSizVQtq-Fw3izsB9Wz9XDRS5m2ZKwtOkd4ZqjJH84Zns7LzFkoYIM6WE/s1600/1245+002.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="480" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEie_5i4Bkp8AKdcQCEmvcfGuTVqtaSGGfd6s0Ig0HhmgVWl3XPI96OAmsajxWw-mfMwjPfwYJK3ckSiCxzWYPgSizVQtq-Fw3izsB9Wz9XDRS5m2ZKwtOkd4ZqjJH84Zns7LzFkoYIM6WE/s640/1245+002.JPG" width="640" /></a></div>
This a sample of some fuel made in the hydrocarbon cracker. Results have varied but I'm trialing various set ups to get consistent usable fuel. The device can make petrol, kero, diesel amongst others. The feedstock can vary to for instance oils and plastic.Excaliburhttp://www.blogger.com/profile/10595000113080348084noreply@blogger.com0tag:blogger.com,1999:blog-3067454529522601128.post-1524059934707800082012-10-05T20:04:00.001+13:002013-09-21T08:08:21.087+12:00Turk burner hydrocarbon cracking pyrolysis prototype<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjJbhxJ_EdhYiyj8shjNrMbp94nXPQIkqpQ2ir7oKMqlnS3zvVZ7IH6XVcfa94y8YARW-qwtB73dDDe8NTGRBVvLvhXcaAyPj2Ufyd3tlB2elkV043OUwvyo2hIiXoDyaj-7uLhDT31bpA/s1600/147896+002.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="480" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjJbhxJ_EdhYiyj8shjNrMbp94nXPQIkqpQ2ir7oKMqlnS3zvVZ7IH6XVcfa94y8YARW-qwtB73dDDe8NTGRBVvLvhXcaAyPj2Ufyd3tlB2elkV043OUwvyo2hIiXoDyaj-7uLhDT31bpA/s640/147896+002.JPG" width="640" /></a></div>
This is my device to convert waste oil to diesel or petrol. The basic principles are simple. Distill oil and break the molecules to shorter chains to create light fuels.<br />
In practice, quite some trial and error is required to get to a working model. The turk pictured above made 13liters of fuels from 14liters of waste oil in its' first run.<br />
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***This has now been dismantled for the parts to build the newest prototype***Excaliburhttp://www.blogger.com/profile/10595000113080348084noreply@blogger.com1