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Fusion Jr. Home Energy Reactor

Fusion Jr. Home Energy Reactor
The “Fusion Jr.” Home Energy Reactor is in essence a mini-generator that derives its power off of combustible waste material (like paper, wood, yard clippings, and even some plastics) inspired by “Mr. Fusion” as seen in the movie “Back to the Future II”. The potential for energy generation is great, and, in fact, this technology was used to power many cars during World War II and is a suggested energy source for developing countries (to provide gas to power stoves mainly). This is a truly unique project (never been done before), and, if completed, you can say that you have successfully converted garbage into electricity!

This is a green technology that derives power from an alternative fuel source that can be built by mostly salvaged components (well, not everything).

The Gasifier unit cleanly converts garbage into a burnable gas often called “syngas” or “woodgas,” then burns it creating heat which can be used to cook food (I have personally used this to cook a pot of soup) or Peltier Cells can convert the heat directly into electricity. The current produced by the Peltier Cells is sent to a Charging Module. The Charging Module charges a rechargeable Storage Battery. The Storage Battery supplies energy to run a Power Inverter. The Power Inverter can be used to run electrical appliances. Later we will see that after setting up the battery, inverter, and charger, turning this into a solar project is as easy as substituting the Fusion Jr. with any solar panel.

The minimum energy expected from one unit is dependent on how many peltier cells are used. Each cell contributes about 3 continuous watts. Potential energy from a Fusion Jr. system is well over 2000 watts, but harnessing all of that energy is difficult, especially since peltier cells are at less than 3% efficient.
Appliances with high watt ratings can be run even with low input because energy is stored in the Storage Battery.
 
 
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Step 1Get a Coffee Can

Get a Coffee Can
«
  • FusionJrDiagram2.png
  • FusionJrDiagram.png
  • ComponentsFusionJr.png
(See Diagrams)
 The Gasifier Unit is one of the most crucial components of the Fusion Jr. system. The Gasifier Unit comes in 3 parts, labeled as A (chimney), B (housing), and C (reactor). Each part comes apart.
Trash is put through the chimney and is ignited using an igniter (a lighter). The trash begins to combust with oxygen supplied through holes at the base of the housing. The oxygen travels from the outside into the housing, then into the reactor through the lower holes. As temperature rises and more trash is supplied, the oxygen supply is cut off as the lower holes are blocked off by embers and ash and the trash can no longer combust. The high temperatures cause the creation of “syngas” which primarily consists of the combustible gases carbon monoxide and hydrogen. The “syngas” does not combust, even though there is a high enough temperature, until it reaches the combustion zone labeled by the diagram. The “syngas” combusts with oxygen supplied by a series of holes. The result of this combustion is the release of carbon dioxide, water vapor, and heat. The Gasifier Unit effectively burns garbage without excessive pollution and smoke. Unfortunately, when starting up the gasifier, when the gasifier runs out of fuel, and during windy conditions, smoke is produced. The Gasifier will provide heat for up to a half hour after the flame dies down.

I used a coffee can, a bean can, a small cookie tin can, and a camping pan to make this setup, but you can experiment with different setups. Puncture holes as dictated by the diagram. More holes provides more oxygen and thus a better burn, while less holes allows for more partial combustion which is needed for the formation of gas. The key is to experiment with oxygen intake. Gasification relies on what is sometimes referred to as "partial combustion," which means that, to produce intermediate flammable gases, you must adjust oxygen available in the combustion zone (the number and size of holes).

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115 comments
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Mar 29, 2012. 10:21 PMAriedeB says:
Could you also use a watercooling system, like those you find in cars to make a better cooling gradient?
Feb 17, 2012. 7:24 PMHomepwner says:
O.K. I thought at first that this was a joke. Now after reading a bit, I think it's one of the coolest things I've seen on IS. I also remember now that I had heard of this tech. on a show that tlc or disc. had a few years ago where they threw a bunch of people out at some ware houses and they had to use whatever was laying around to build a survival community. >VERY COOL, bookmarked, future project!
Mar 13, 2012. 9:46 AMtinker234 says:
the colony called a gasfier
Jan 21, 2012. 9:22 PMTAKuhn says:
Hello this may have been answered but I’m too inpatient to read all 100 + replies you have here ;}
Would it be safe to run a turbine off the top of the chimney to generate power if the turbine is heat resistant?
thanks
Jul 20, 2011. 7:14 PMkarnold70 says:
I would love to see someone do a " Solar Steam Trubine" using a Fresnel lens. I think it could be really amazing, and I think you might be the guy to do it.
Jan 17, 2012. 4:27 PMANDY! says:
Those big rear projection tvs have Fresnel lenses if you weren't aware...
Dec 7, 2011. 7:36 PMMatrix-technician says:
Hello there! There is actually an instructable on how to make your own glass fresnel lense from an old tv. I can't recall it's adress atm but try looking it up. :p
Sep 22, 2011. 7:38 PMFuzzeeDee says:
Originally light houses used GLASS Fresnel lenses and these type were far more efficient than modern cheap plastic ones. I don't remember what temperatures they could withstand but it should be about the same as leaded glass so there should be no issue with your proposed use. Hope this info is useful.
Nov 6, 2011. 1:28 AMscarrillo says:
GREAT JOB GURU! YOUR AN INSPIRATION TO US ALL! THERE IS HOPE FOR HUMANITY I JUST KNOW IT!^_^
Oct 23, 2011. 5:23 PMearthwindwater says:
Nice! Good job.
Sep 18, 2011. 9:53 AMlkurtz2 says:
Any alterations needed to produce biochar as well? This process also produces wood gas, but the biochar effectively is a carbon sink as well as a soil amendment increasing food production. ( I think it depends on temperature of the oxygen-free environment of the wood fuel).
Aug 22, 2011. 10:30 PMKi1o says:
Using charcoal instead of wood will produce a cleaner gas and will not produce volatiles and does not have the excess water content of wood.
Aug 22, 2011. 9:39 PMKi1o says:
In actuality, however, this is not a Fusion reactor. This is a wood gas generator. But I commend you for your efforts. I actually recently found out about the wood gas generator when I was watching a new show on the Science Channel called Stuck with Hackett. I've been searching for a way to build one and I stumbled onto your Instructable. Thanks Man, it helped a lot.
Aug 19, 2011. 12:08 AMbsax211 says:
I think what you have done here is pretty awesome. Its basically a regenerative thermal oxidizer/ gassifier combo. Have you thought of maybe making a downdraft gassifier? Its design is pretty simple. Maybe a gas clean up system to run a small engine? You could use sodium bicarb. Heck, you could use it to reclaim metals and glass if it was changed a bit.....I know Im going on and on. Ive been working with gassifiers for a few years now and have wanted to do something similar to this but living in an apartment has limited my pyro induced fun. Either way, I think this is pretty awesome, as long as people realize a lot of voc's produce H2S and that gassifying plastics is not usually a good idea. Sticking to wood and paper and coal are pretty safe though. Also, I am pretty sure burning syngas does release CO2, since syngas is mostly just CO and H2, add O2 and you should get H2O and CO2. Great Instructable!
Aug 8, 2011. 6:04 PMlhouse says:
Instead of a battery bank and/or direct wire of peltier cells, try this

http://en.wikipedia.org/wiki/Sodium_sulphate

The stuff as a decahydrate melts at 32.4 C and stores heat quite nicely, is cheap and/or easy to make. This might be able to be pushed through a larger container and more fit to mesh with peltier cells for a much longer period.
Jul 22, 2011. 8:07 AMda winksta says:
The natural gas from a gasification unit can be used to run any 2 or 4 stroke gasoline engine/generator
Aug 3, 2011. 1:45 PMextrordinary1 says:
I just happen to have a 4 stroke motor collecting dust in the garage. Has about 300 miles on it. Now you went and got some gears turnin in my brain driving me nuts! LOL

I've been wanting to take the scooter apart, 150 cc and fuel the engine with gasification. Idea was to make a 3 wheeler with a single drive rear wheel, low profile ride. Thanks
Jul 30, 2011. 9:13 PMavatar_i says:
?! More info for a novice who doesn't understand those big words?
No, not seriously, but I am new to power generating and really want to learn more about running a small engine on non-petrol fuel.

A few years ago I attached an alternator [generator?] from an auto to a bicycle and mamanged to get enough electricity to charge a 12 volt battery to run a radio and some lights during a week long power failure, in the winter, without frying myself. A Miracle I suspect!

This idea would seriously save my legs and back!
Jul 29, 2011. 7:41 AMkrowfarmer says:
It can also be connected to an internal combustion engine, though it may need to be scaled up in size (depending on the size of the engine). Do a search for "Construction of a Simplified Wood Gas Generator for Fueling Internal Combustion Engines in a Petroleum Emergency" for further information. It is a publication from FEMA.
Jul 22, 2011. 7:23 PMjconway1 says:
It may burn cleanly ... but isn't the production of Co2 the out and out thing that we are also trying to avoid due to lack of available greenary?

I don't mean to be a bugger but maybe if we built a green wall stucture to house your design (as seen in other instructables here) one might be able to self - Carbon offset too.

Just an idea!

Nice toy though.
Jme
Jul 26, 2011. 5:41 AMjconway1 says:
Hi, you're quite right and I appologise. I'm looking at ways of making ethanol to run my car with (away from the mainstream) and confused myself with carbon monoxide a bit there - sorry!

Have you attempted attaching a "sterling enine" to your burner atall? ... the reason that I ask is that I live in Brazil and things like Peltier cells are not very easy to come by. Ordered off the internet things cost double here because of import tax - so we tend to have to fabricate things ourselves, the easier - the better.

At the moment I'm toying with adding your burner to a sterling engine of somesort - or gearing it up for an inverted washing machine motor-generator - or even a permanent magnet windmill type gig, I'm not sure yet but I really appreciate your work here, thankyou very much for this instructable.
Jul 24, 2011. 8:38 PMjholmes3 says:
what if instead of the peltier cells you set it up as a steam engine where this is used to boil the water and it's on a condenser loop to reuse water and run a turbine that is wired to the battery and converter. maybe you could get more watts setting it up like that .
Jul 24, 2011. 1:22 PMValtis says:
All of you who make this wood gas creator keep in mind that wood gas contains carbon monoxide (27%) before ignition, which is very toxic and if you don´t show the respect, stay outside or keep some track of the levels if you necessarily must be inside.

Carbon monoxide poisoning is the most common type of fatal air poisoning in many countries.[21] Carbon monoxide is colorless, odorless, and tasteless, but highly toxic. It combines with hemoglobin to produce carboxyhemoglobin, which is ineffective for delivering oxygen to bodily tissues. Concentrations as low as 667 ppm may cause up to 50% of the body's hemoglobin to convert to carboxyhemoglobin.[22] A level of 50% carboxyhemoglobin may result in seizure, coma, and fatality. In the United States, the OSHA limits long-term workplace exposure levels above 50 ppm.[23] Within short time scales, carbon monoxide absorption is cumulative, since the half-life is about 5 h in fresh air (see main article).
The most common symptoms of carbon monoxide poisoning may resemble other types of poisonings and infections, including symptoms such as headache, nausea, vomiting, dizziness, fatigue and a feeling of weakness. Infants may be irritable and feed poorly. Neurological signs include confusion, disorientation, visual disturbance, syncope and seizures.[7]
Some descriptions of carbon monoxide poisoning include retinal hemorrhages, and an abnormal cherry-red blood hue.[24] In most clinical diagnoses these signs are seldom seen.[7]
Carbon monoxide binds to other molecules such as myoglobin and mitochondrial cytochrome oxidase. Exposures to carbon monoxide may cause significant damage to the heart and central nervous system, especially to the globus pallidus,[25] often with long-term sequelae. Carbon monoxide may have severe adverse effects on the fetus of a pregnant woman.

If you want to read more about carbon monoxide: http://en.wikipedia.org/wiki/Carbon_monoxide

If you pay wood gas enough attention and use it safely it is both fun and all that stuff. Nice instruction btw, GJ!
Jul 23, 2011. 8:08 AMfozzy13 says:
This is pretty cool. I've wanted to/thought about building a woodgas stove coupled with Peltier elements for a while. Thanks for posting!
Jul 18, 2011. 1:21 PMJohan8335 says:
This is one of the most interesting, well thought out/researched and actually help full Instructable I have seen in a long time. One can see that you know a lot about the subject, and this is something I would like to try on a somewhat bigger scale.
I am in the process in creating a “eco practical” off the grid game ranch in South Africa, and this is part of a solution to two of my biggest problems.
#1 getting rid of the guests and my garbage.
#2 generating electricity.
Any other Ideas from the good citizens of Instructables are welcome.
Thanks.
Jul 22, 2011. 1:35 AMOle bally says:
HI Johann, please have a look at Henry Moray 'a sea of energy' on the net as well as Tesla...man if it can work on a big enough scale...power for free!!
Actually I invite anyone to have a look and see if this can be done for real...just where I am in Zim it's a real bind to get the stuff in!
Jul 20, 2011. 12:01 PMChrishugh says:
How will you get repeat business if you burn your guests for fuel?
Jul 20, 2011. 7:10 PMJohan8335 says:
There are plenty of tourists in SA for replacements
LOL
Jul 19, 2011. 1:40 PMdh1 says:
I have as a concept a solar powered idea that I'm going to be utilizing with these Peltier - as a proof of concept - One the one side - copper sheet with the hot side attached, on the cooling side a copper sheet with cooling fins, a mister system and fans ... In Arizona (very similar climate to Australia 40+ centigrade temperatures) - It could easily push 200+ degrees on the copper plate hot side and cool with misting and fans down to make it the 68 degree temperature differentiation that would provide the max amount of wattage from the devices... an array of 30 of these (90-138.6watt versions) can be found cheap and would push anywhere from 2 to 4 Kwh of electricity on a good day.... modify to attach to a gasifier for times of cooler weather or cloudy days and you could easily generate enough electricity to power a house (in az running the a/c at 75 degrees).... That's my thoughts as to how to make these more efficient without using ice...
To the author: Can you specify what your temperature differences are and the output of your peltier devices at the temperature differences so we can get better estimates on what we can expect to see in a real life application?
Sep 22, 2011. 8:10 PMFuzzeeDee says:
There is another solution for converting heat directly to electricity you may have not considered. It uses a principle called the "ceibek" (I may be misspelling it) effect. How this works is you can take almost any dissimilar metals in direct contact with each other and subject one half to a higher temperature than the other and a current will be produced. One good example is to take a steel or iron bolt and tightly wrap copper wire around about 2/3 of the bolt then place the 1/3 bare portion of bolt or rod on a hot surface. Even a few degrees differential will produce current. I can't remember the math involved to calculate expected output based on temperature differential and mated surface area between the two metals. Some experiments would tell you what two metals give the best results. This method is still popular in countries where cabins too far from the grid combined with weather patterns not suitable for either wind or solar power such as the mountains of Switzerland. If I can find the paperwork I have on it, I will scan the pages and post them somewhere, when I first heard about it in 1996 I sent a query out on a news group and got a reply asking for a mailing address. Without thinking I replied with my address and forgot about it. About 6 weeks later I got a very thick manila legal sized envelope from a university in Belgium. When I opened it I found about 100 pages of formulas, research results, metallurgical test results, current real world uses, etc. A little simple bit of testing showed me it worked and if I remember correctly the research paper said up to 17 or 18 percent efficiency had been realized in a lab setting with real world applications around 11 or 12 percent efficient being typical. Hope this helps folks. regards, Dave
Oct 20, 2011. 4:02 PMdhill16 says:
http://en.wikipedia.org/wiki/Thermoelectric_effect

This page explains the process as well as the formulas.
It is known as the "seebeck" effects.
Oct 20, 2011. 6:47 PMJohan8335 says:
Thanks dhill16 and FuzzeeDee, this is all Very interesting and helpful
Jul 20, 2011. 11:19 AMJohan8335 says:
I was thinking in the same line, for on my farm it can reach up to 40 Deg Celsius (104 Fahrenheit or 313 Kelvin) in the day time.
As we all know refrigeration, cooking and water heating for showers are the main consumers. So this is what I am concentrating on.

Shower water is easy with solar heating system (maybe need gas for supplement)

Cooking is possible with solar devises but not all practical and not usable “indoors” so gas will have to do (For now).

Refrigeration, now this is what I want to concentrate on here. Solar panels with a battery system will work but batteries are hi maintenance and the right batteries are “hi cost”.

So this is my Idea and would like to know any comment from you guys where one may make it more efficient. This is still in Idea form so don’t judge me to loudly LOL
Two copper plates separated with spacers for water to flow between and painted black on the outside mounted on the roof. Water pipes running (as short as possible and insulated) down to my fridge (standard with all working parts removed). Mount Peltier cells inside the fridge with “warm side” protruding to the outside.
The “hot side” of the Peltier’s will be heated by the hot water from the roof, creating a current to run #1 a fan inside the fridge and #2 a small circulation pump to circulate the water.
The problem is to get the fridge cold in the first place to start the action. The fridge being an insulated and mainly closed unit could be started with ice or frozen anything. This should get the cycle going. Maybe even have an additional Cold water system running inside the fridge.
Now that I actually sit and type this from my thoughts it is sounding a bit like perpetual motion, even the fact that the sun is providing energy.

Maybe have Peltier cells on the copper plate powering Pelrier cells in the fridge, to replace the water piping system and using a water system to cool the Peltier cells on the roof and in the fridge.

Maybe even have an additional Cold water system running inside the fridge.
Let me know what you guys are thinking, remember its only an Idea and from here We can work.
Jul 23, 2011. 9:12 AMcarmatic says:
The problem with using peltiers with the fridge is that you are still dumping heat from the sun into the fridge, after they have passed through the peltier
In fact you are mostly dumping sun heat into the fridge outright after a small amount of heat has been converted into electricity by the peltiers

You need a definite place for the heat coming out of the peltiers to go, somehow getting it into the ground would be a good place to start
Jul 17, 2011. 2:30 PMlperkins says:
If you have money to spend, you can find 3000 Farad capacitors on Ebay. These are larger per unit of energy storage than lead-acid batteries, also, they are more expensive. However the number of charge-discharge cycles they can withstand is usually over 100,000, and they can charge and discharge as fast as you can move the electricity.
Jul 21, 2011. 2:26 PMskrubol says:
3000 farads is less than 1 amp-hour (1 farad means at 1 amp draw, the cap will discharge 1 volt per second.) Energy capacity of a cap is E=.5 * v^2 * c (in joules.) So a 2600 farad, 2.5v cap (around $30 on ebay,) will have 8125 joules (equivalent to watt-seconds,) of energy. This is 2.6 watt-hours. A typical car battery sized deep cycle battery will have somewhere between 500 and 2000 watt-hours. Also, you have to drain the cap to 0v to get all its energy.
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Author:TheHomebrewGuru(TheHomebrewGuru Channel)
Hello I'm Mad Scientist Trevor Nestor. If you like my instructables see my youtube channel! http://www.youtube.com/user/HomebrewGuru?feature=mhee