15 Gal Coal Vac System Tutorial

 
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Wiz
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Post by Wiz » Sat. Dec. 15, 2012 8:14 am

Great idea Wiz, thanks for posting. A few questions.

1.) I didn't even see where you had the Shop Vac. Can it be placed anywhere?
I added system after you stopped in.
2.) What did you clean the last bit of the grease out of the barrel with or did the garage already have it cleaned out for you?
Barrel had 90 lube oil in it, didn't bother to clean it. I'm setting up system for friend today using grease drum, I just wipe it down with rags.
3.) 15 gallons of coal is about 150 pounds? So once a day you can feed your hopper slowly but surely all the coal it would need, maybe even 2 days. That is really a great idea
I'm keeping hopper filled and barrel daily, this allowing me to have no dust at all. Now I'm keeping shop clean ;)


 
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Wiz
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Post by Wiz » Sat. Dec. 15, 2012 8:22 pm

do you think it would work with buck sized coal?
Yes it will vacuum buck size coal

 
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Post by Wiz » Sun. Jan. 13, 2013 7:37 pm

Added a cyclone dust collector to help reduce coal ash from entering shopvac. Wife was going to hang me if I didn't return her Dyson canister back. So for now had to make one until I find old broken dyson.
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Post by VigIIPeaBurner » Sun. Jan. 13, 2013 8:17 pm

Wiz wrote:Added a cyclone dust collector to help reduce coal ash from entering shopvac. Wife was going to hang me if I didn't return her Dyson canister back. So for now had to make one until I find old broken dyson.
Nice DIY job on the cyclone :up: Interested to find out how it works with the coal dust. What diameters did you settle on for the top and bottom and how high did you make the cone?

 
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Post by Wiz » Mon. Jan. 14, 2013 5:38 am

What diameters did you settle on for the top and bottom and how high did you make the cone?
Cone is 2 ft long. top dia is 7 in and bottom 3 1/2 in. all joints seal with caulk then duck tape. Hardware store on way home to pick up 2 quick connects the test.

 
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Post by Paulie » Mon. Jan. 14, 2013 8:37 am

Very cool system, well done.

 
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Post by Wiz » Tue. Jan. 22, 2013 5:48 am

I tested cyclone to compare results without it. 500 lbs test without it, vac was clean proir and new bag. Problem I was having is bag would clog with coal ash then blow out of vac. :o Dust cloud in shop.
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Now results with it. Note used different vac with filter. Very little dust on filter seen on bottom of image. Much cleaner using cyclone. :? images sideways.
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Post by VigIIPeaBurner » Tue. Jan. 22, 2013 6:22 am

Approaching perfection :D
  • :clap: :clap:

 
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Post by coalkirk » Tue. Jan. 22, 2013 7:43 am

dust deputy.jpg
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I've had good results since using my dust deputy.

 
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Post by Wiz » Sun. Jul. 14, 2013 2:38 pm

Switching from Rice to Buckwheat I've realize improvements were needed to system. Another issue some members have come across was lost suction, collapsing of plastic drums and little amount of coal being transfer. The smoother the coal tube the better transfer rate will be, if using flex tube that has ridges inside expect slower feed rates. Placement of air tube on coal feed pipe needs to be on top side of pipe, any other way will create lost air needed. So now the improvement, Coal Vac Turbo System. Just like anything else, more speed means more power. I added a 4hp vac to my 6hp setup, by doing this feed rate is excellent and sucking coal up 8 ft pipe with no more issues.

[youtube]https://www.youtube.com/watch?v=Bdsn4TXTF30 [/youtube]

 
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Post by paulmunroe » Tue. Aug. 20, 2013 12:27 pm

Like the new turbo system but why have you not included a dust cyclone separator in this setup?
Also have you put small holes in the coal pickup/intake pipe to stop air blocks or does the 1/2 inch pipe that you have connected to the head of the intake pipe stop any air blocks?

 
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Post by Wiz » Tue. Aug. 20, 2013 4:53 pm

paulmunroe wrote:Like the new turbo system but why have you not included a dust cyclone separator in this setup?
Also have you put small holes in the coal pickup/intake pipe to stop air blocks or does the 1/2 inch pipe that you have connected to the head of the intake pipe stop any air blocks?
once I connected 2 shop vacs to system there was no more issue with air blocks (loss suction). Using 1 1/2 feed tube only no holes needed, you'll be able to limit air tube also. No dust separator since switching to buckwheat coal, very clean compare to rice.

 
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Post by johnniecuse » Mon. Feb. 17, 2014 9:15 pm

I have been fiddling with this setup for a while now. I have been mildly successful. Basically, I have two vacs connected.
The intake pipe is 8' of 1-1/2" PVC on a 45* angle rising about 7' to a 15' horizontal run of 2" PVC. It worked great. System performance drops off dramatically when the filters on the vacs get loaded with dust. I take them out every few days, blow them out with the compressor, re-install and I am back to a good performing system.

Should I install a cyclone separator?

Any other suggestions?

 
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Post by titleist1 » Mon. Feb. 17, 2014 9:51 pm

What are the vac's rated hp? I think from what you posted you are using the pleated canister filters to catch the dust, have you tried a drywall dust bag in the shop vac's?

 
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Post by Dirty Steve » Tue. Feb. 18, 2014 7:57 am

johnniecuse,

I have a cyclone dust seperator inline from each shop vac to the top of my 15 gal drum. I also use a high efficiency dust bag inside each shop vac and a HEPA filter in each shop vac. 6.0 and 6.5 rated vaccums. I use a 16 foot long flexible 2 inch suction house to the side of the 15 gallon drum. I vaccum from the top of the pile. I will be able to reach all 4 corners of the floor of my bin. Very little dust in either shop vac bag and almost no dust on the hepa filters. Each dust seperator has 4-5 inches in the bottom of the five gallon pails. It is alot of "riggar mer ol" but I have not shoveled one piece of coal in over 4 tons used so far. ;) My weakest link so far as been a cover of sorts over my coal boiler hopper under the 15 gal drum for ultimate dust control. That has been my goal with this entire project. Some day we want to finish off the basement. Hope this helps.

Steve


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