3:17 pm
October 6, 2016
Hi everybody,
My friend and I converted an old natural gas fired brass melting furnace to a 3 burner propane forge and it won't get hot enough for welding or even hot enough for thicker steel.
The furnace has the heavy type fire brick lining it's interior. It's about 18 inches deep and maybe 10 inches high inside. We drilled through the upper outside corner at about 45 degrees to make holes for the 3 Ron Reil type burners with the main tube made from 3/4 iron pipe. We have the stainless tips extending into the furnace about 1 inch. There are two vents holes on top of the furnace that are about 1-1/2 in dia. We have to keep the front door open when heating longer metal because it's hinged from the top. We have had the propane pressure up to 30-35 psi and the furnace is roaring but it still isn't heating the steel hot enough.
What are we doing wrong? Too much heat leaking out the door and vents?? Fire brick soaking up all the BTUs? Inside opening too large? We need more psi on the propane?
Thanks, Roy7:44 pm
NWBA Member
September 28, 2016
Kind of a shot in the dark here as I am quite new. But seeing as heat travels upwards you are probably losing an awful lot of your heat through those vertical vents. I would try putting a soft heat brick over them.
You also might try forcing more air into the furnace via a blower rather than just using negative pressure.
Emphasis on me being really new and by no means a professional.
11:17 pm
NWBA Member
December 27, 2014
Oh yes, definitely, those two holes on top are releasing a heckofalotta heat. Like Darien said, those should be plugged up somehow. Now, sometimes the forge needs some way of releasing pressure and some holes are necessary, but if you're going to have a vent anywhere, it should be on the side. Heat rises, right?
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5:41 pm
NWBA Member
November 14, 2010
Definitly plug the holes on top. Also if the interior is made of hard firebrick, they are massive heat sinks and will take up to 30-45 minutes at least to get up to temp. and will slow down any high heat from happening for a while. If this was as you say a brass furnace 1) Brass melts at a much lower temp. than steel welds at, and they may not have built it to specs. that we would want as far as refractory mtls. 2) If it was a brass furnace, give up hope for welding in it as it is probably contaminated with copper, one of the sure ways to NOT get a decent weld. Relining it will remove or seal up any contamination. You may want to reline it with Kaowool buttered with hi temp mortar for the sides and top, and castable refractory cement for the bottom and an inch or so up the sides to resist flux, as flus will eat up kaowoll like water on cotton candy. As far as the door goes, remove it and set up a brick shelf and a system of hard firebricks to allow you to adjust your door to the size of stock you want to push in. This will minimize the heat exausting out of the forge. Venturi burners can weld if designed well, and on these Ron Reil burners you might make a disk with a tab for screwing over the large air inlets so that you can throttle back the cold air coming in as this further cools the forge down. All air, other than needed for combustion, will cool down your forge. Try covering one of these holes a bit with tin foil and opening it a little at a time until you get good combustion on that burner. this will give you an idea of the ideal fuel air mix for your burners. Just about every forge needs some tuning for optimal efficiency. Think of a tin can lid big enough to completely block the air inlet of the burner and add two tabs opposite of each other. Bend one up at 90 degrees for a handle for adjustment, and drill the other and the opening of the bell reducer with a small drill and tap for a screw and washer for a pivot to allow you to pivot it to throttle the in coming air flow into each burner.
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