[TheForge] Melted Flares & Refractory Liner

[Ed F]

----- Original Message -----
From: "Dave Brown" <quahog@tds.net>
To: <theforge@mailman.qth.net>
Sent: Sunday, March 09, 2003 9:08 PM
Subject: Re: [TheForge] Melted Flares & Refractory Liner


> At 20:11 03/09/03 -0600, you wrote:
> >Hi All,
> >
> >I'm running the awesome robust reliable cheap burners Jay Hayes sells.
> >Problem is I keep melting the flares.  I replace them after 200 hours or
so.
> >Yah, I think she gets hot enough, thank you.  But I think the flare
> >deterioration has a lot to do with the 1 1/2" castible refractory liner I
> >have (backed by 3" ceramic fiber).  I have about 1/4" clearance all
around
> >the flare to the refractory.
>
> Ed,
>
> There could be several factors contributing to this.
>
> 1.  Does the end of the flare extend, even a little, into the fire
chamber?

No.  1/4" recessed into the liner the first set.  Went to ss and recessed
tip  1/2" behind the liner into the insulation the second time.  First time
they burned off pretty fast.  Second time they mushrommed.  Jay figured back
pressure from recessing them could be a problem.


> 2.  Especially if you are operating with the back and front opening's
> closed relatively tight, then you may be forcing some of the combustion
> gases and secondary burn flame up along side of the flare.

I use bricks for doors and it's almost never tight.

>
> 3.  Running at too low of pressure for long periods can result in the
> air/fuel mixture igniting before the  mix passes the end of the flare
tube.

Jay's valving setup came with an idle circuit I ususally set at about 2 psi.
I idle down when hammering if there isn't more stocking needing higher heat
in the forge.  But usually I keep feeding cold steel into the forge as I
work so I can always be buisy.  So in the end I rarly run it at low pressure
and almost never for more than a few minutes.

> 4.  The early burn in 3 above can also be triggered by having the flare
> tube too long.  Assuming that your flare is a separate piece from the
> mixing tube, loosen the set screw(s) on the flare and shorten it a bit.

I have 8" nipples and adjust the flares near the typical settings.  The
flares on the ones I'm tuning now extend about 1 1/4" past the tube.    I
have found that there is one best spot.  I have played with nipple length
and found there is almost no leeway from the 8".  I tried making one 8 1/4"
and the burner sucked.  Then I cut it to 8" and it worked perfectly.  I had
similar expereiences making it shorter.

> 5.  Could also be something else that I'm not thinking of right now.  What
> pressure, orifice size, and mixing tube are  you using?

I run 3 to 15 psi usually.  I used a 58 or 59 orifice last time.  6o this
time.  Jay thought going a bit smaller might help the flare issue.  The
nipple is 3/4" pipe.


> Dave Brown
>
> Good Health is merely the slowest possible rate at which one can die.
>
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