Steam Engine Construction Set: Difference between revisions

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=Introduction=
#REDIRECT [[Steam Engine Intro]]
 
Steam engines are a robust energy source which played a main role in the industrial devolution, and may now be a viable candidate as an engine of the post-industrial revolution. [http://tinytechindia.com/steamengine.htm Tinytech] in India manufactures steam engines for various industrial swadeshi applications, primarily in India. We believe that steam engines, coupled to flash steam generators, are also relevant as an appropriate technology choice in the 'developed' world. As such, we are proposing an open source steam engine project, to deliver an appropriate technology, modern steam engine:
*Open design
*Scalable in power from 5 to 100 horsepower
*May utilize electronic valving for mechanical simplification
*May be coupled direcly to linear dynamo - feasibility study required
In particular, Factor e Farm is interested in utilizing these steam engines in the LifeTrac line of tractors, cars, and solar turbine electrical generators.
 
=Design=
[[Link title]]==Engine==
 
===Typical Engines===
 
Typical steam engine cylinders are made from cast iron. (What is the best metal to use for a steam engine?) Given that water is the working fluid, lubrication is required in the cylinder. (Is there any way to prevent corrosion otherwise?)
 
*Cylinder - cylinder is made from cast iron.
**To cast this cylinder from scrap iron, use a (how many?) pound melt, and use a simple melting furnace such as (here?)
 
The simplest way to cast a cylinder
 
===Green Steam Engine===
 
An alternative engine design that may be worthy of further evaluation can be found [http://www.greensteamengine.com/index.html] here.  It looks as though o-rings are used in place of traditional tight tolerance cast iron cylinder boring.  Presumably this method is only good for low pressure and temperature steam. The linkage and valve system is highly innovated and would require no precision machining.
 
*Discussion of the Green steam engine:http://www.alternative-energy-news.info/green-steam-energy/ It does indeed seem that the o-ring method of sealing is incapable of handling high steam temps and pressures and the design is therefore inherently inefficient.
 
*Marcin says: I looked at this in detail 2 years ago, and purchased plans. When I asked for references of people who built this engine, the inventor did not provide me with any. I became suspicious about the effectiveness of the engine. Since then, I've heard reports from several sources that longevity and performance are questionable. In summary, if this worked as stated, we would see a large number of implementations on the internet. Since these are not to be seen, it does not appear to be a promising design.
 
 
 
Steam Engine History:
 
http://www.egr.msu.edu/~lira/supp/steam/
 
A History of the Growth of  the Steam Engine: [http://books.google.com/books?hl=en&id=YiNMAAAAMAAJ&dq=steam+engine&printsec=frontcover&source=web&ots=upjyQA2XIn&sig=gBtrUy-6kRF-HaMr8T2FXppi4KY&sa=X&oi=book_result&resnum=2&ct=result]
 
A Catechism of the Steam Engine:[http://www.gutenberg.org/etext/10998]
 
 
Steam Engine Primers/Groups:
 
http://www.pioneer.net/~carlich/RSE/RSEprimer.html
 
http://www.the-nerds.org/Steam-101.html
 
Promising forum with large library of working steam engine plans: http://www.paddleducks.co.uk/
 
 
Engine Plans/Products:
 
http://www.pioneer.net/~carlich/RSE/RSEengines.html
 
http://www.nearfutures.com/products.htm
 
http://www.greensteamengine.com/products.htm
 
Triple Expansion Steam Engine Prints: http://www.carferries.com/triple/
 
Lindsey Publications:http://www.lindsaybks.com/prod/sub/engines.html
 
http://www.grahamind.com/
 
http://quasiturbine.promci.qc.ca/Presse/SteamMuller050721.pdf
 
These guys claim 30% efficiency on their non compunding multi cylinder steam engine http://www.energiprojekt.com/?product
 
'''*3kW steam engine for $1375''': http://www.thesustainablevillage.com/servlet/display/products/byCat/71/441/2557/
 
Lots of Plans: http://www.john-tom.com/html/SteamPlans.html
 
A nice simple doubel engine plan: http://openfarmtech.org/images/e/e0/MichelNiggelTwin.pdf
 
Misc:
 
Vegetable Oil Based Lubricant:http://www.steamenginelube.com/chelesic.htm
 
Homebrew Steam Engine Generator:http://www.otherpower.com/steamengine.shtml
 
Steam Engine Manuf. Links: http://cedesign.net/steam/steam-links1.htm
 
Oil Free Steam Engine Design for Vehicles: http://six6.region-stuttgart.de/sixcms/media.php/773/23_Platell_P.pdf
 
Flash Steam Engine, Could this be advantageous http://www.huzar-power.com/steam_engines/revival/flash_steam.htm
 
'''Engineering Specs:'''
 
[[Image:Steam Engine Cylinder Size Non-Condensing.jpg]]
 
[[Image:Steam Engine Cylinder Size Condensing.jpg]]
 
Nick R. says, what are the limits to lathe boring diameters in cast iron?  This [http://www.john-tom.com/MyPlans/Steam%20Engines/MarineEngine.pdf] method of construction looks simple and attractive if it could be scaled up enough?
 
==Boiler==
A simple boiler implementation involves a [[Babington_Burner]] heating the inside of a 6 inch metal pipe of 1/8" wall thickness. A 100 foot long coil of 1/2 inch steel tubing is placed inside this coil, and an electronically-controlled [[Valve delivery system]] (note: in steam engine case, the 'solar boiler' in last link is replaced by the above 100-foot coil of steel tubing.
[[Category:Research Projects]]
===Materials===
*Stainless steel tubing at McMaster Carr, $130 for 100 feet of 1/2" tubing - type 304 stainless - item number 8989K67 at http://mcmaster.com
*200 psi pressure relief valve - source?
 
 
Boiler Fuel:
For transportation vehicles some biomass fuel energy densification is required.  Pyrolisis fuels without elaborate processing look prmoising here is a brief summary of some methods http://www.ars.usda.gov/sp2UserFiles/Program/307/biomasstoDiesel/RobertBrown&JenniferHolmgrenpresentationslides.pdf
http://www.biomasscombustion.com/horizontal_grate_technology.htm
 
Stationary applications can probably get by with a simple style grate biomass boiler. http://www.biomasscombustion.com/horizontal_grate_technology.htm
 
=Design Evolution=
*Initial design, 1.8.09 -
 
[[Image:Steam Engine Concept.jpeg]]
 
[[Image:Crankshaft eccentric.jpeg]]
 
3D Initial Model 1/19/09
[[Image:Crank_Assembly_2.jpeg]]
 
==Bill Of Materials To Date==
 
QTY Description Price Location
*1 Cylinder 38.03 [http://www.discountsteel.com/index.cfm/go/main.itemDisplay/itemID/45.htm]
*1 Piston 3" x 5/8" Cold rolled Steel 9.97 [http://www.discountsteel.com/index.cfm/go/main.itemDisplay/itemID/13.htm]
*1 Shaft 1" 13.01 [http://www.discountsteel.com/index.cfm/go/main.itemDisplay/itemID/13.htm]
*2 Plate 1/2"x6"x6" 17.71 [http://www.discountsteel.com/index.cfm/go/main.itemDisplay/itemID/4.htm]
*1 Flywheel 8"x2.5" Cold Rolled Steel 74.3 [http://www.discountsteel.com/index.cfm/go/main.itemDisplay/itemID/13.htm]
*1 Eccentric 4.5" x .5" Cold rolled 13.95 [http://www.discountsteel.com/index.cfm/go/main.itemDisplay/itemID/13.htm]
*2 .5" Dia Pin 1.75" Long 6.29 [http://www.discountsteel.com/index.cfm/go/main.itemDisplay/itemID/13.htm]
*1 Lower Connecting rod 5/8"x1"x6" 9.91 [http://www.discountsteel.com/index.cfm/go/main.itemDisplay/itemID/11.htm]
*4 3/4"x1.5' Threaded Rod 14.64 [http://www.grainger.com/Grainger/items/2GRR4?cm_mmc=Google%20Base-_-Fasteners-_-Bolts-_-2GRR4]
Baseplate TBD
Stuffing Box TBD
*1 6' Sch 80 Steam Pipe 43.7 [http://www.amazon.com/dp/B001NPLLW2/ref=sr_1_3?ie=UTF8&m=AH1JDG368QYFS]
 
'''TOTAL 241.51'''
 
=Example of Fully Integrated Steam Energy System=
[[Image:Integrated_Energy_System.jpeg]]
 
Description of this system by author and excellent background info on homepower steam http://www.fastonline.org/CD3WD_40/JF/JF_OTHER/BIG/Reciprocating%20Steam%20Engine.pdf
 
Apparently Skip Goebel thinks similar to me about electronically controlled steam engines taken from http://www.mail-archive.com/sustainablelorgbiofuel@sustainablelists.org/msg01818.html
 
Fwd from [EMAIL PROTECTED]:
 
Two things that I see on the very near horizon that puts steam back on top
both efficiency and cost wise in bio fuels.
  First is catalized refractory.  For years, I have been getting a wonderful
catalytic reaction using 'cera-blanket' as a liner in my wood burning
fireboxes.  Now, by layering a layer of perforated firebrick, behind that a
layer of cerablanket, behind that thin steel plate that is perforated and an
airgap behind that with casing on the other side.  This allows air to be
pumped from the casing thru the blanket and then thru the perf brick.  We are
talking small amounts here of air, but enough to ignite and glow.  It is
similar to indoor propane heaters used today(ventless).
  With such a reaction between the esters and carbon monoxide burning in such
a way as to really put out the i.r. rays, The firebox is improved in many
ways.  Including smaller amount of headroom from fuel pile to cieling.  This
allows fuel pile to be surrounded by the high radiation/refraction
refractory.  In doing so, the fuel pile distills quite easily, and requires
far less incoming air thru the grate which is a big source of nox.  The
gasses driven off the fuel pile can now be reignited in a controlled
situation and where most beneficial.
  Of even bigger benefit, is this kind of firebox can utilize wood 3' or even
longer.  This signifigantly reduces material handling energy and cost
(hogging).  It also makes hand firing feasable.  That means a lot in third
world countries.
 
  The biggest news for steam is electric valves.  Finally, they are
commercially available.  Volvo will put them out in a year.  Valve timing on
a piston type steam engine is everything.  Without getting too fancy already,
I manufacture engines that eat far less steam than a turbine up to about
500hp.  The cost is less than half also.
  If I can operate the valve via electric sylinoid instead of mechanical, I
have infinite adjustment on cutoff and expansion which allows for perfect
governing and a consumption rate of 10-15lbs per hp, vs 50-70 on a turbine.
Again, this is in the up to 500hp bracket, but in the real world, biomass
falls into this catagory.  Only the big lumbermills do it larger and they are
not everywhere.  And....they are more user friendly and cheaper.
  I am making the statement now that the catalytic refractories and the
electric valving will become the foundation for new technologies in the
combustion of bio fuels.  If you do the math, you will see that the fuel
rates come close to diesel engines, but without all the hassles.  Boilers are
more versatile as diesel engines are limited to mainly motive powers and
electricity is the main one.  While a boiler can give you the means of
production and manufacturing.  This means a genuine return on investment.
  ...it could be that the grant process will become history. :)
 
Skip Goebel
Sensible Steam International
www.sensiblesteam.com
www.apin.com.pe
 
 
Electronic Solenoid Valve Info: http://www.gwlisk.com/tech_info.html
 
=Tooling Requirements=
 
==Metal Casting==
*see [[Foundry]] for more details
 
Waste vegetable oil furnace design
http://www.backyardmetalcasting.com/oilburners03.html
[[Foundry.pdf]]
[[Pattern_Making.pdf]]
 
www.budgetcastingsupply.com
http://www.metalwebnews.com/howto/furnace/furnace.html
www.creativecastingco.com
www.host33.com/casting
www.backyardmetalcasting.com
www.emainc.com/radnor/sand.htm
http://oak.cats.ohiou.edu/~dw120996/..._of_metals.htm
 
--------------------------------------------------------------------------------
 
 
==Lathe==
**Romig bed lathe type - from Multimachine - [[Image:Romig.jpg]]
**Simple prototype, $486 in materials BOM:
***2 bearings, $50
***2 mouning plates, 1/2"x6" angle - $40
***4 Shaft Collars - $20
***2" shaft - $20
***DOM tubing, 3", 2" ID - $15
***8 3/4" bolts for table - $16
***Chuck plate - $40
***Bolts for chuck - $20
***Nuts and bolts for DOM - $5
***XY table - $70 off shelf at Enco - [http://www.cartertools.com/newjose3.html]
*** Tool post - $10
***table plate - $30
***2 bags of cement, 80 lb each - $20
***sand, gravel - $10
***'''TOTAL - $316'''
**High performance, 2/1000" accuracy with proper technique, stock parts, 1000 lb radial and 200 lb axial load capacity
 
==Flash Steam Generator==
 
**Coil bending jig - $400
**Stainless steel coil, 150 feet - $200
**Babington fittings and metal - $100
**Dremel tool - $40
**Dremel micro drill press - $40
 
==Electrical Generator==
 
=Open Source Steam=
 
Steam power is not taught in general. For mastering this topic, we need a Steam Power Reading List.
*I have some of this material from Tom Kimmel, of [http://www.kimmelsteampower.com/ Kimmel Steam Power]
*Mike Brown offers a reading list [http://www.mikebrownsolutions.com/order.htm here]
 
=Letters and Communications=
 
Letter to VK Desai of Tinytech Plants -
 
Dear VK,
 
Can you share your knowledge of steam power with us?
 
In order to make our solar turbine a success, we need to build the steam engine at low cost - in house. If I do my own labor, use our machine shop, and use casting in house, then the price for the engine parts should be about $150 for a 3 hp engine. Do you think that is realistic?
 
Please share with me your basic design. Simple drawings on the back of an envelope would do. I am smart at studying design. Please just give me the essentials and material specifications.
 
Please respond, or put your notes up directly at:
 
http://openfarmtech.org/index.php?title=Steam_Engine_Construction_Set
 
If you have any pictures of steam engines in fabrication, please share.
 
Sincerely,
 
Marcin
 
Response from Mike Brown Steam engines
 
Nick,
 
Skip Goebel is in Peru, do you have the DVD he did on building a prototype boiler?
I doubt if your solenoid valve will last six months on a steam engine.
Sorry, we don't get involved in other people's engineering projects (we average two emails like yours a day).
 
Best wishes,
Mike
 
 
nick raaum wrote:
Mr. Brown,
I have been working lately on developing a simple horizontal uniflow steam of 3" x3.5" bore and stroke that is controlled by an electronic solenoid valve and a small programmabale logic controller.  My full intention is to power this engine with a gasifier monotube style boiler and utilize the exhaust in a 750 gallon thermal storage tank for home heating purposes.  In my research in this project I found reference to Skip Goebel's work through your site.
that Skip Goebel may already be building a boiler of similar design, if possible could you give me his contact info?  I would also be interested to know if you have given any thought to developing an electronically valved steam engine?  I intend to try an asco 1/2" direct acting steam valve that claims to cycle at 800cycles/min for a million plus cycles.  I intend to run my engine at 100rpm which in theory may give my controll of the cutoff ratio in increments of .25.  This obviously will not be efficient but I want to try the concept first. Perhaps you know more about what this actually would take?  In any case I do appreciate your time to read this email and I hope you keep up the good work in small scale steam power development.
Sincerely,
Nick Raaum
 
Why did Skip go to Peru:  Excerpt from Peru forum
 
Skip says "well, why do you think i am here?
yep, always put my money where my libertarian heart is
 
and remember, it is never tecnology, it is always politics.
at this moment, our world is back into mercantilism and now that means banks are in control. no concern for you and me. "you are either with us or against us". -if you want to work for THIS bank.
so to hell with philosophizing ourselves out of this crisis. we are getting our just desserts. and the reality is we are too comfortable to do hwat is really right. thus, we enter the era of contented slavery. ambition is fully regulated. the rich dont want competition.
i came here 9 years ago and fell in love with the land. pure libertarianism and all that goes with it. i have all my inventions here and this is the best place to launch them.....someday.....
wanna invest? 
 
 
----
 
=Development Team=
*Nick Raaum - Project Manager. He works at a coal power plant, but his visions are different.
 
[[Image:nick.jpg]]
 
*Marcin Jakubowski
[[Image:marcin_sm.jpg]]
 
[[Category:Solar_Turbine]]

Latest revision as of 17:11, 23 March 2011

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