Waste Oil Furnace For Melting Metal

 by rjeblogue
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Four things inspired me to try an oil fired foundry.Detailed instructions on the net,gallons of oil in my garage from changing my own oil, hassles and cost of constantly filling my propane tank and my recent discovery of an endless source of free oil/gas mix removed from vehicles that are being crushed.
 
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Step 1: The Parts Needed

oil_burner_drawing.jpg
I found This cast iron pipe fitting at the salvage yard. The blower was also salvaged and the intake and exhaust nipples are pipe nipples I had to buy. I drip the oil down from the top center and have the fan on bottom with the hot flame coming out the top. I preheat the double ended stainless steel cone shaped jigger with my torch for two minutes through the removeable-blower hole until it is glowing red hot ,start the oil dripping and quickly remove the torch and add the blower. A permanent built in Torch head for pre-heat might work better. The blower is controlled with a house lamp dimmer for varying degrees of hi-lo (not recommended for inductance motors). After I was sure the contraption would work I encased it in a can rammed full of refractory
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craftystein says: Jan 21, 2013. 11:01 AM
This is really cool and really well done. I think it is interesting to weigh the cost of doing this yourself versus having it done for you. I have included a link to a pricing guide for manufactured oil furnaces as well. Would be interested to hear your feedback and comments on usefulness of potentially building these for different uses, etc.

http://www.qualitysmith.com/request/articles/articles-heating/oil-furnace-cost/
Cool-fool says: Mar 10, 2012. 9:34 PM
I'm thinking about making something like this and have two questions:

1) What is preventing the flame from moving backwards up the fuel line to the reservoir? (Is it because there's no oxygen in the fuel line? Is there anything one could do to make this safer?)

2) Is there any advantage to this shot-glass "carburetor" method over the Brute's pseudo-fuel-injection method? I would think that the method you're using here wastes a lot of heat through the carburetor chamber itself, because the flame must move through the carburetor.

P.S. "The Brute" burner that I'm talking about is here: http://www.backyardmetalcasting.com/oilburners09.html

Thanks for your advice!
Nagarok in reply to Cool-foolMar 17, 2012. 8:15 PM
For the first question
I'm pretty sure it is that
also the fact that for oil/petrol to burn, it must be a vapor already would have a big effect here. adding it straight into a fire this doesn't mean much, because the oil vaporizes from the heat of the fire, then burns. But in the pipe, the liquid oil would be moving fast enough to push the vapor out the end of the pipe before it has a chance to heat the rest up to vapor.

If you wanted to, you could add a one-way valve somewhere in that so that the oil can go into the chamber, but not flow back up. Or another design feature is to create a "Pop" valve in the oil reservoir. Basically means cutting a small square out of the top, then taping a single layer of cling wrap, or thin tape over the top. So it's still air tight, but if any force builds up in the chamber i.e. explosion, it will go through that hole, instead of actually going boom.
germeten in reply to NagarokJan 11, 2013. 11:56 PM
Actually oil is pretty hard to ignite, and in an enclosed area in an absence of air (like the oil line), even more so. Gravity keeps the oil flowing down-hill, there's no pressure to speak of to push it back up. No amount of heat at the far end of the line is going to explode your reservoir, (oil is not an explosive) but does burn well once lit. An oil fire outside your foundry is something you want to take safety steps to prevent. Great idea, man.
rudolphdiesel says: Aug 24, 2012. 9:49 PM
"who knows when" self destruct device.
etopsirhc says: Jul 7, 2011. 12:41 PM
watch out when it self destructs , u dont want to be around when a molten metal bomb explodes XD
mieszalniapasz says: Jul 25, 2008. 7:20 AM
(removed by author or community request)
Esmagamus in reply to mieszalniapaszSep 1, 2008. 7:00 PM
It would be if it were a babington burner. A great design, by the way. It's capable of handling lots of grime and metal shavings, but it's not very compact for most home uses.
sillywilly in reply to EsmagamusApr 17, 2011. 8:13 PM
You can build Babington burners big or small! Go look at examples at the Yahoo group "altfuelbabington" You may have to join to look at all the pics but it's an easy join! User "mitchrx7" has a really neat automated one, probably the classiest one on there!
rjeblogue (author) in reply to mieszalniapaszJul 25, 2008. 12:15 PM
Hi - Not compressed. Just air from a blower. An automotive heater fan would work great.
Jimmy Proton says: Mar 9, 2011. 4:20 PM
That wouldn't get hot enough to melt iron.
Esmagamus says: Jul 15, 2008. 6:36 PM
Nice! Some more ideas for my future oil heater! I don't feel like feeding it with wood all the time.
sillywilly in reply to EsmagamusDec 26, 2009. 8:26 PM
Esmagamus,
Just add a tee to the oil line (with additional shutoff) to feed waste paint thinner or perhaps kerosene to warm up the chamber. I have read where this works quite well and usually only takes a few minutes.
Robotics_Geek in reply to sillywillyJan 20, 2011. 4:03 PM
In mine I just squirt a bulb (an ounce?) of kerosene into the chamber and barely crack the fuel and light. When the waste oil mixes with the kerosene it will burn longer once it's warm enough I open the fuel more. I added copper nails and other copper screws etc. to act as wicks to the bottom of my furnace. It helps dissipate the fuel better and helps it light easier.
Furnace.jpg
mazeka.14 says: Aug 29, 2009. 6:44 PM
how hot does it get?
raceryz350 in reply to mazeka.14May 31, 2010. 8:39 PM
thats what she said
0087adam in reply to raceryz350Aug 2, 2010. 1:20 AM
Lol...
ticoun says: May 21, 2010. 1:47 PM
never use homemade refractory with a waste oil burner, because it will melt down pretty fast and turn into glass. if you plan to make a waste oil burner, you must make your furnace with a commercial refractory hotface that's rated for at least iron melting temperatures.
eckopariah says: Feb 11, 2010. 12:49 AM
Looks very similar to my aluminum melts with charcoal as a fuel. The metal isn't getting hot enough to melt completely, and you're left with some unmelted metal/slag/dross on the bottom of the crucible. I must say, your burner design looks somewhat inefficient, however VERY creative. I might recommend eliminating the mixing/preheating chamber, and just have the fuel drip right into the airstream, similar to L. Oliver's "Brute" furnace. much simpler design, and he can melt iron with it. That will save you fuel and increase temperatures in a shorter time, because you're not preheating a chamber before the main furnace.
briackman says: Jul 5, 2009. 1:54 PM
ey, can you make one with vegetable oil, probably not but i'm just wondering
NewB007 in reply to briackmanDec 27, 2009. 3:55 PM
One ancient civilization (I think it was the Greeks) used olive oil to smelt ore.  I would expect that different vegetable oils would burn at roughly the same temperatures, so it should work.
rjeblogue (author) in reply to briackmanJul 5, 2009. 3:16 PM
Yes you can., As one of the readers suggested, checkout www.backyardmetalcasting.com
Benson1 says: Jun 17, 2009. 3:08 PM
couldn't you make one out of bricks?
rjeblogue (author) in reply to Benson1Jun 17, 2009. 4:12 PM
Yes..but it might take more heat to melt your metal if your bricks are absorbing the heat rather than reflecting it. The homemade refractory material has things like Perlite that have insulation properties.They do make special refractory furnace bricks or you could even use the homemade refractory material and mold your own bricks.
Benson1 in reply to rjeblogueJun 17, 2009. 10:09 PM
yeah what he said.
paddlesport says: May 3, 2009. 2:43 PM
We used a similar setup on a larger scale; 55 gallon drum cut in half with firebrick lining, in a college pottery class for making Raku pottery. We used an old vacuum cleaner motor for that.
spudster says: Feb 18, 2009. 7:57 AM
whats an ice maker fitting
rjeblogue (author) in reply to spudsterFeb 18, 2009. 12:51 PM
It is a small brass ball valve with 1/4 o.d. compression fittings used for shutting off or turning on the 1/4" plastic water line to the back of a refridgerator for the ice maker water supply line, or sometimes used in the shutoff tot he water suply in an evaporative cooler (swamp cooler). Available in most hardware stores in the US or maybe even on Ebay for under $5 .
deathpanda says: Jan 31, 2009. 9:35 AM
what about adding wire coming from the air intake tube and into the shot glass then putting nicrome wire in a coil at the bottom of the shot glass. then all you have to do add a switch and power source and it should heat up and ignite the oil in the shot glass then when you have a sustainable burn going turn the wire off and let it do its thing. the nicrome has a melting point of approx 2500 c i believe so it should not melt from the heat. and you could house the lead wires in ceramic tubes so they don't ground out. just an idea
brown68 says: May 19, 2008. 9:56 AM
great job, but can you explain to me what is a steel brake line?. I'm interested in building a kiln for firing pottery using waste oil burners
lasermaster3531 in reply to brown68Jan 30, 2009. 1:38 PM
a steel brake line is a pipe that's made of steel to pipe brake fluid to the brakes on a car. Hence the name.
Esmagamus in reply to brown68Aug 27, 2008. 9:41 PM
You should expect to have some problems with glazes if your burners produce any kind of solid contaminants, or even some chemical ones.
rjeblogue (author) in reply to EsmagamusAug 27, 2008. 11:24 PM
The article I read about using waste oil to heat a pottery kiln was in a third world country where the convenience of clean electricity is not an option. I am guessing it was to fire clay vessels for carrying water. I agree, they may not be glazed vessels of beauty but I'd bet they would hold water.
rjeblogue (author) in reply to rjeblogueAug 27, 2008. 11:25 PM
(The kiln was in the 3rd world country, not the article) LOL
Esmagamus in reply to rjeblogueAug 28, 2008. 7:34 AM
So that changes everything. Electrical kilns aren't very common because using gas is a lot cheaper than electricity. Pottery that is not too porous can probably be waterproofed with grease, but that can cause sanitary problems that would be avoidable with glazing, provided it would be food safe glaze, with no lead or other heavy metals (you'd be amazed with the kind of undeclared dangerous chemicals that come in those bags of glazing powder, and the reason why there are almost no available MSDS on glazes is keeping formulas away from other companies). Probably metal cans are a better sanitary choice than unglazed pottery. Still, there's research to be done.
jtobako in reply to EsmagamusJan 31, 2009. 8:20 AM
Porous pottery has advantages over sealed ones-like the self-cooling by evaporation and the ability of low-fired cookware to be set on a fire without the heat-shock shattering it. Any problems with waste oil contamination could be solved by using a muffle-an inner liner between the flame and the wares. This could be part of the kiln or smaller containers (with lids) make of higher firing clays.
rbneville in reply to brown68Aug 9, 2008. 3:20 PM
a steel break line is the line that goes to the brakes on a bike
lasermaster3531 in reply to rbnevilleJan 30, 2009. 1:42 PM
bikes don'thave metal brake lines. even high-end bikes that use fluid have nylon(or Kevlar or steel)-reinforced plastic lines. most bikes don't even have brake fluid!
l3lanket in reply to lasermaster3531Oct 8, 2012. 3:49 AM
Wouldn't you consider steel to be a type of metal?
Derin in reply to rbnevilleAug 17, 2008. 12:19 PM
NO NO NO NO NOOOOOOOOOOOOOOOOOO!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!You got confused,dude.The steel brake line he was talking is used to carry brake oil in a car!
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