15 Gal Coal Vac System Tutorial

Re: 15 Gal Coal Vac System Tutorial

PostBy: Wiz On: Sat Dec 15, 2012 9:14 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 ;)
Wiz
 
Stoker Coal Boiler: Keystoker Ka 6
Coal Size/Type: Casey Junk Coal :(

Re: 15 Gal Coal Vac System Tutorial

PostBy: Wiz On: Sat Dec 15, 2012 9:22 pm

do you think it would work with buck sized coal?


Yes it will vacuum buck size coal
Wiz
 
Stoker Coal Boiler: Keystoker Ka 6
Coal Size/Type: Casey Junk Coal :(

Re: 15 Gal Coal Vac System Tutorial

PostBy: Wiz On: Sun Jan 13, 2013 8:37 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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Wiz
 
Stoker Coal Boiler: Keystoker Ka 6
Coal Size/Type: Casey Junk Coal :(


Re: 15 Gal Coal Vac System Tutorial

PostBy: VigIIPeaBurner On: Sun Jan 13, 2013 9:17 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?
VigIIPeaBurner
 
Hot Air Coal Stoker Furnace: Keystoker Koker
Hand Fed Coal Stove: Vermont Casting Vigilant II 2310
Other Heating: #2 Oil Furnace

Re: 15 Gal Coal Vac System Tutorial

PostBy: Wiz On: Mon Jan 14, 2013 6:38 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.
Wiz
 
Stoker Coal Boiler: Keystoker Ka 6
Coal Size/Type: Casey Junk Coal :(

Re: 15 Gal Coal Vac System Tutorial

PostBy: Paulie On: Mon Jan 14, 2013 9:37 am

Very cool system, well done.
Paulie
 
Stove/Furnace Make: leisure Line
Stove/Furnace Model: Pioneer

Re: 15 Gal Coal Vac System Tutorial

PostBy: Wiz On: Tue Jan 22, 2013 6:48 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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Wiz
 
Stoker Coal Boiler: Keystoker Ka 6
Coal Size/Type: Casey Junk Coal :(

Re: 15 Gal Coal Vac System Tutorial

PostBy: VigIIPeaBurner On: Tue Jan 22, 2013 7:22 am

Approaching perfection :D

    :clap: :clap:
VigIIPeaBurner
 
Hot Air Coal Stoker Furnace: Keystoker Koker
Hand Fed Coal Stove: Vermont Casting Vigilant II 2310
Other Heating: #2 Oil Furnace

Re: 15 Gal Coal Vac System Tutorial

PostBy: coalkirk On: Tue Jan 22, 2013 8:43 am

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I've had good results since using my dust deputy.
coalkirk
 
Stoker Coal Boiler: Harman VF3000
Coal Size/Type: antrhcite/rice coal

Re: 15 Gal Coal Vac System Tutorial

PostBy: Wiz On: 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.

Wiz
 
Stoker Coal Boiler: Keystoker Ka 6
Coal Size/Type: Casey Junk Coal :(

Re: 15 Gal Coal Vac System Tutorial

PostBy: paulmunroe On: 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?
paulmunroe
 

Re: 15 Gal Coal Vac System Tutorial

PostBy: Wiz On: 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.
Wiz
 
Stoker Coal Boiler: Keystoker Ka 6
Coal Size/Type: Casey Junk Coal :(

Re: 15 Gal Coal Vac System Tutorial

PostBy: johnniecuse On: Mon Feb 17, 2014 10:15 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?
johnniecuse
 
Stoker Coal Boiler: Leisure Line 110K Boiler
Coal Size/Type: Rice

Re: 15 Gal Coal Vac System Tutorial

PostBy: titleist1 On: Mon Feb 17, 2014 10:51 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?
titleist1
 
Hot Air Coal Stoker Stove: Harman Mag Stoker (old style) one in basement, one in workshop
Hand Fed Coal Stove: Harman Mark III on standby for long power outages
Coal Size/Type: Rice/Anthracite; Nut/Anthracite

Re: 15 Gal Coal Vac System Tutorial

PostBy: Dirty Steve On: Tue Feb 18, 2014 8:57 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
Dirty Steve
 
Stoker Coal Boiler: Keystoker KA-6
Coal Size/Type: Rice
Other Heating: Oil- Off line
Stove/Furnace Make: Keystoker
Stove/Furnace Model: KA-6