๐Ÿ“˜ Guides โ€บ ๐Ÿ’ก Heat, light & power ยท ๐Ÿ†˜ Emergency ยท ๐Ÿ“‡ Index Aโ€“Z

โ™จ๏ธ Heat into Work and Power

Can a fire do more than keep you warm? Yes: it can pump water, turn a saw, charge a phone and even make ice. This guide gives the honest numbers first, then covers stove-top thermoelectric generators, small steam engines and boiler safety, hot-air (Stirling) engines, refrigerators that run on a flame, and other ways to put heat to work. The books added for this guide are in Southern-Oregon\Off-Grid-Power\Heat-Engines (download list: local/library-files.txt). Wood gas, the best way to run a generator on wood, is in the Fuel guide and the Engines guide; storing heat in water and stone is in the Storing Energy guide. Where this guide works a number out, it says (arithmetic); check it with the Practical Math guide or the Calculator.

The short version


๐Ÿงฎ The honest numbers: what a pound of wood can do

A pound of dry wood holds about 8,600 BTU of heat, and a stove gets roughly 50% of it into the house (Aprovecho Capturing Heat Three, p. 18). That is about 2.5 kWh of heat in the wood and 1.25 kWh delivered (1 kWh = 3,412 BTU) (arithmetic). One horsepower is 746 watts (DOE Wind Power for Farms, p. 27), so one horsepower for an hour is 2,545 BTU of work (arithmetic).

Way of using the heat Share of the wood's heat you get back From 1 lb of dry wood Worth building?
Heat used as heat (house, cooking, hot water, drying) About 50% as useful heat About 1.25 kWh of heat Yes, always first
Wood gas in an engine generator About 12% as electricity, at a good steady load About 0.3 kWh (3 lb per kWh) Yes, if you can build and tend a gasifier
Hot-air (Stirling) engine 7โ€“10% for the best small factory engines; homemade ones far less 25โ€“200 Wh For slow pumping; homemade ones are teaching models
Small steam engine (no condenser) About 2โ€“4% as shaft work 50โ€“100 Wh of work; 10โ€“25 lb of wood per kWh Only for heavy mechanical work, with a real boiler and a trained operator
Thermoelectric module on a stove About 3% of the heat that passes through it; well under 1% of the stove's whole fire A few watt-hours, but the heat still warms the room Yes, as a free extra while you heat or cook

Where these come from (arithmetic, from the pages named):

What it means: a stove that heats the house and also charges the phones is a good deal. A fire built only to make electricity is not: a steam plant burns 10 to 25 lb of wood for each kWh, about what a fridge uses in a day (rule of thumb). If you need real power, see wood gas in the Fuel guide, and solar and creek hydro in the Off-Grid Power guide.

๐Ÿ“š Go deeper: NASA Stirling Engine Design Manual, pp. 7โ€“8 โ€” why heat engines all need a hot side and a cold side; Aprovecho, pp. 16โ€“18 โ€” how much heat a house really needs.

๐Ÿ”‹ Stove-top thermoelectric power

How a thermoelectric generator works

Heat one end of a joint between two different metals and a small voltage appears across it: the Seebeck effect (Kuphaldt Lessons in Electric Circuits vol. 1, p. 320). Many junctions in series make a thermopile: heat goes into one set and the other set is "bonded to a heat sink of some sort (air- or water-cooled)" (p. 323). A modern module (TEG, thermoelectric generator) is a flat square tile packed with such junctions. Power comes from the difference in temperature between its two faces, so a hot stove with a warm cold side makes almost nothing (rule of thumb). You can see the effect with a copper wire, an iron wire, a candle and a voltmeter (Kuphaldt vol. 6, p. 117).

What to expect in watts

Choosing modules: TEG or salvaged Peltier

Keeping the cold side cold

The cold side is half the machine. Wikipedia: "The cold side must be cooled by air or water" (Thermoelectric generator).

  1. Clamp the module firmly between the hot plate and a heat sink (a finned block from an old computer or amplifier) with a thin smear of heat-sink paste on both faces (rule of thumb).
  2. Water cooling works best: a flat-bottomed pot or a closed metal box of water on top of the module. The water warms, so top it up or swap it; never let it boil dry (rule of thumb).
  3. Air cooling: a big finned heat sink, ideally with a small fan run from the module's own output (rule of thumb).
  4. A module whose two faces reach the same temperature makes nothing; if the output sags after an hour, the cold side has warmed up (rule of thumb).

Getting usable 5 V and 12 V out of it

A single module gives a few volts that rise and fall with the fire, so it needs a regulator between it and anything you care about (rule of thumb):

๐Ÿ“š Go deeper: DOE Wood Stove Design Challenge report โ€” the measured stoves and how they were tested (p. 21); Kuphaldt vol. 1, pp. 320โ€“324 โ€” thermocouples, thermopiles and the Peltier effect.

๐Ÿš‚ Steam: what a small engine can do

What steam is good at: steady, heavy mechanical work from any fuel that burns. Farm steam engines were belted to threshing machines, and a steam engine copes with a load that changes a lot: Maggard's farm engine might "do eight horse work one day and sixteen horse work the next day" (Maggard Rough and Tumble, p. 11).

What a small one needs:

Turning a pump, saw or generator

Condensing and reusing the water

๐Ÿ’ฅ Boiler safety: read this before you light a fire under anything closed

Why boilers explode

"The one great cause of boiler explosion is the inability of the boiler to withstand the pressure to which it is subjected at the time" (Hawkins Maxims, p. 284). Hawkins lists the reasons (pp. 284โ€“285):

  1. Bad design (not enough stays and braces).
  2. Bad workmanship.
  3. Bad material: blisters and flaws in the plate.
  4. Too much pressure: a reckless operator, a wrong gauge or a stuck safety valve.
  5. Overheated plates from low water.
  6. Scale and mud that keep the water off the iron.

The farm engineer's version: "A properly constructed boiler never explodes, except from low water or high pressure" (Maggard, p. 20). The damage comes from the hot water flashing into steam all at once when the shell lets go (Maxims, p. 284; Boiler explosion).

What never to use as a boiler

(Rule of thumb, from the failures in the books)

The safety valve

Water level: the gauge glass and the try-cocks

The fusible plug

A brass plug filled with soft metal sits in the crown sheet over the fire. If the water drops below it, the metal melts and steam blows into the fire to put it out (Maggard, p. 81; fusible plugs; Fusible plug). Some states required one by law (Maxims, p. 175); Maggard thought it made operators careless (p. 81). Keep the plug, but never count on it: it is a last warning, not a water gauge (rule of thumb).

If the water is low

The Navy's rule, for when the water goes below the bottom of the glass or you don't know whether it is high or low (Boilerman, p. 324):

  1. Stop the fire. On a wood fire, smother it with dirt or ashes (Maggard, p. 162); never throw water into the firebox, which can crack the sheets (same page).
  2. Shut the feed. "You must never feed water to a boiler in an attempt to restore the water level after a low-water casualty!" (Boilerman, p. 324). Hawkins agrees: "Don't pump cold water into a hot boiler" (Maxims, p. 48).
  3. Shut off the steam to the engine and get people away from the boiler (rule of thumb).
  4. Let it cool slowly, then look inside for bulged or scorched plates before you use it again (rule of thumb).

Testing with water, never with steam or air

Low-pressure and no-pressure choices

๐Ÿ“š Go deeper: Hawkins Maxims and Instructions for the Boiler Room โ€” firing, the morning checks, explosions (pp. 284โ€“285); Maggard Rough and Tumble Engineering โ€” running a farm engine and boiler, with questions and answers (pp. 140โ€“162); Navy Boilerman 3 & 2 โ€” water-level emergencies, gauge glasses and safety valves.

๐ŸŒ€ Stirling and hot-air engines

How they work

A hot-air engine (today called a Stirling engine) keeps the same air shut inside. One end is heated by a fire and the other is kept cool. A loose piston called the displacer (or transfer piston) shuffles the air between the hot end, where it expands and pushes the power piston, and the cold end, where it shrinks again; a heavy flywheel carries it round (Collins, pp. 215โ€“216; how it works; Stirling engine). Better engines add a regenerator, a mesh or plates between the hot and cold ends that soaks up heat from the air going one way and gives it back on the way back (Hawkins New Catechism, p. 324).

Why bother: they can "use any source of heat", run quietly and last a long time (NASA Stirling Manual, p. 7); there is no boiler to burst. Why they lost out: the old air engines had "high reliability and safety, but low specific power" (same page): big and heavy for the work they do.

What they really deliver

Best uses: pumping water and slow work

A simple build from pipe fittings

Collins's model hot-air engine is made from plumbing parts (Boys' Book of Engine-Building, pp. 215โ€“226; cross-section; the finished engine):

  1. Hot cylinder: a 4-inch length of iron pipe a little over 2 inches across, a threaded cap on each end, the top cap drilled for the displacer rod (p. 216). (The old scan blurs the fractions; check the drawing.)
  2. Displacer: a smaller capped pipe with a hardwood plug, deliberately loose so air can pass around it, on a rod through the top cap (pp. 217โ€“218).
  3. Power cylinder: "half as large as the expansion cylinder", with a piston of the same metal that fits "pretty accurately, as it is not packed" (pp. 219โ€“220).
  4. Connecting pipe from the top of the hot cylinder to the power cylinder, and a crankshaft with two cranks, one for each piston (pp. 221โ€“223).
  5. A heavy 5- or 6-inch flywheel and a firebox with air holes at top and bottom (pp. 224โ€“226).
  6. To run it: a flame centered under the bottom of the hot cylinder, then "Give the flywheel a couple of turns" (p. 226).

The same layout scaled up, with a water-cooled top and a regenerator, is the old pumping engine (rule of thumb).

๐Ÿ“š Go deeper: Hawkins New Catechism, pp. 319โ€“324 โ€” the Ericsson and Rider pumping engines, with sectional drawings; NASA Stirling Engine Design Manual โ€” the engineering, for anyone designing a serious engine.

โ„๏ธ Heat into cold: absorption refrigerators and ice makers

How a flame makes cold

Gas and kerosene refrigerators use the absorption system: a small flame drives ammonia out of water under pressure until it condenses to a liquid, and the liquid boils off again in the cold box, soaking up heat. There are no moving parts; "The Servel is used in RV's now. Modern kerosene and propane refrigerators use this system" (Aprovecho, p. 37; Absorption refrigerator). The sealed system is under real pressure: the tested unit held 1.52 lb of ammonia and was pressure-tested to 717 psi (NBS report, p. 9). Never drill, cut, bend or heat its tubing (rule of thumb).

Keeping an absorption refrigerator running

From the National Bureau of Standards tests, for the Army, of a propane-fired household-type absorption refrigerator:

Fuel: how long a tank lasts

The tested fridge was rated for 1,300โ€“1,600 BTU an hour (NBS report, p. 9). With the burner on all day that is 31,000โ€“38,000 BTU, or about โ…“ to โ…– of a gallon of propane a day at 91,000 BTU a gallon (Univ. of Minnesota EB 436, p. 16) (arithmetic). The thermostat turns the flame down much of the time, so real use is less. A kerosene model burning the same heat would use about ยผ gallon a day (kerosene: 135,000 BTU a gallon, same page) (arithmetic).

Burner care and carbon monoxide

(Rule of thumb unless cited)

Solar and fire-driven ice makers

What a 12-volt "thermoelectric cooler" can do

The plug-in camping coolers use Peltier modules run backwards. They cool only about 20 ยฐC (36 ยฐF) below the room and are much less efficient than a compressor fridge (Thermoelectric heat pump). Fine for a drive, poor for living off a battery (rule of thumb). Their modules are worth saving for stove-top power (above).

๐Ÿ”ง Other ways to put heat to work

๐Ÿงฏ Safety: burns, steam, carbon monoxide and fire

โš ๏ธ Old advice in the library to ignore

Book says Do this instead
On low water out on the road, run the engine's front end onto high ground "so that the water would raise over the crown sheet and thus make it safe to pump up the water" (Maggard, p. 162). Never feed water after a low-water scare: kill the fire, shut the feed, let it cool, then inspect (Navy Boilerman, p. 324).
A cork in the filling hole of a toy boiler "will act as a safety valve, for it will blow out before the boiler blows up" (Collins, p. 74). A cork can swell, stick or be pushed in too hard. Any boiler, even a toy, gets a real weighted or spring safety valve (rule of thumb).
Pump the boiler up with a bicycle pump and run the engine on compressed air "without steam and, naturally, without fire" (Collins, p. 125). Never put air pressure in a boiler: compressed air stores energy and bursts violently. Test with water only (rule of thumb).
"If you find a thin plate, what would you do? Put a patch on" (Maxims, pp. 131โ€“132). That was a licensed boilermaker's job. A thinned, cracked or patched boiler is retired from pressure use (rule of thumb).
Calk stack leaks "with a mixture of asbestos wicking and red lead" (Boilerman, p. 359). No asbestos and no red lead: use high-temperature stove cement or furnace sealant (rule of thumb).
Refill a melted fusible plug with babbitt by pouring it in (Maggard, p. 83). Fit a proper replacement plug of the right melting point, and find out why the water got low (rule of thumb).
A homemade Icy Ball from propane cylinders (Aprovecho, p. 37). Aprovecho itself stopped over "the potential for explosion" (same page). Use a factory absorption fridge.

๐Ÿ–ผ๏ธ Pictures & diagrams

โ†‘ Contents