WASTE OIL HEATING THAT MAKES SENSE
How a waste oil burner works:
There are four different process elements needed in order to properly incinerate waste motor oil, waste vegetable oil, and other from of spent oils:
- The oil must be “preheated” to 150° F (66° C). This ensures that any solid parts of the oil are properly melted - and increases the oil’s ability to be ignited.
- The heated oil must be “atomized” - or sprayed.
- The heated, atomized oil must be ignited.
- All these processes must be controlled in a safe, efficient way.
The KingBuilt Boiler and Furnace systems excel at all four of these processes - most important being our patented preheat system. Read on to see the difference with typical, electrical heater preheat systems and KingBuilt's patented Hydronic Preheat System.
The problem with using Electric Heaters to preheat oil:
Every other burner on the market today uses some type of electrical heater - which is in direct contact with the oil - to preheat the oil. Although this method works - and has for many years - there are four specific problems that it causes.
Problem One - Energy Costs: Electric heaters use high wattage electrical heating elements that require an outside source of energy that consumes a significant amount of electricity. These electrical elements take a long time to heat up the oil, typically 5 - 15 minutes, and because of this the oil typically stays preheated between burn cycles, using even more energy. Customers are losing a percentage of their oil energy savings due to the high electrical consumption that these electric heaters take.
Problem Two - Efficiency: Electric heaters are slow to react, creating constant temperature fluctuations in the preheat process. This creates many problems, one being that sometimes the oil does not always get hot enough. Because of this, the oil does not always burn efficiently. Sometimes, the oil does not even get hot enough to burn, causing the fire that was created by the igniter to go out.
To get around this, systems with electric heaters to preheat oil keep their igniters going constantly to insure a constant fire. This uses more electricity and wears out the igniter very quickly, and on most systems it has to be replaced at least once every season.
Problem Three - Safety Hazards: Electric heaters pose several safety hazards. Burners that use this method to preheat oil have vast safety systems set up to prevent a fire.
These safety systems are extremely complex with sensors, switches, wiring and controllers to prevent a hazardous condition. These safety hazards are caused specifically from the temperature fluctuations caused from preheating the oil using an electric heater. At the low end of the electric heaters temperature swing, the quality of oil atomization decreases. When oil cools, it thickens, creating larger droplets. These larger droplets, if not completely incinerated, will project past the flame where they can accumulate and build up unburned fuel inside the furnace or boiler. This unburned oil fuel can pose a serious safety hazard.
Because of high temperatures of the electrical elements, electric heater's preheat systems must implement vast safety systems to prevent a fire. In the event that an electric heater was to fail causing an element to remain energized, another potential fire hazard could occur.
Problem Four - Oil Carbonization: The main problem with using an electric heater to preheat oil is carbonization of the oil. The coagulation of carbonized oil inside the passageways of the preheat device restricts the oil flow causing inconsistent combustion and eventual equipment failure. Carbon build up inside the oil channels insulates the oil from the heat source, making the oil unable to reach a high enough temperature to ignite. Eventually the prior art's preheat device must be removed from the heating appliance, disassembled, cleaned out, reassembled and reinstalled back onto the heating appliance. This process is called overhauling, and can cost up to $800 and must be done every season with most waste oil burners. Overhauling costs an owner a significant amount of time and money to keep the system operable.
With this method of preheating, oil is vulnerable to overheating at the high peak of a temperature swing. Over heated oil produces carbon crystals within the preheat device causing coagulation and clogging of the oil passageway and nozzle resulting in equipment failure. Oil is vulnerable to carbonization at temperatures as low as 90°C (194°F). The surface temperature of an energized electric element can reach up to 200°C and up to 400°F.
There are two main reasons that significant oil carbonization happens with electric heater preheat systems. The first is that - because electric heaters are slow to react - they cause large temperature fluctuations. On the high end of these temperature fluctuations, the oil gets overheated and carbonizes.
The second reason is that - because the oil takes a long time to heat up (5-15 minutes), the oil is typically kept within the preheat system between burn cycles, constantly being heated and over-heated.
KingBuilt's Hydronic Preheat System:
KingBuilt has a patented hydronic preheat system for their burners that transfers heat energy from a heated liquid (water) to the oil just prior to being incinerated. When installed on a boiler, it is able to utilize the heat energy created by the combustion process itself versus consuming electricity to create heat energy for preheating.
Conservative: A significant advantage of the hydronic preheat system is having the option of capturing and utilizing heat energy from the combustion process to preheat oil rather than consuming electricity to create heat energy for preheating. The method of using water does not overheat oil, eliminating the many problems caused by carbonized oil creation and large preheat temperature fluctuations as found in electric heaters. Therefore, the cost of incinerating multiple oil fuels is significantly less.
With a hydronically controlled preheat system; the oil is heated rapidly, typically within 15 to 30 seconds, and is heated just prior to a burn cycle. Because of the high speed of heat conduction from the heated liquid to oil, this invention does not need to keep the dormant oil inside the preheat device heated in between burn cycles, eliminating the costs of the electrical energy consumption needed to keep the dormant oil heated between burn cycles.
Efficient: By using hot water to heat oil instead of an electric device, we completely eliminate any temperature fluctuations in the oil - and by heating the oil just prior to combustion, we insure that the oil is always at the optimum temperature for combustions when it is atomized (or sprayed). This means that our system is always running as efficiently as possible.
And, since our oil is always at the optimum temperature for combustion, we can be positive that once a flame is started, it will not go out. Because of this, we only need to run our igniter for 25 seconds at the start of each burn cycle, significantly increasing the life of the igniter - up to 5 years!
On top of all this, our two-stage air system and our air turbine also significantly increase the efficiency of our burners!
Safe: Using a heated liquid to preheat oil is extremely safe. No fire hazard is caused by circulating water between the heated water source and the oil. The control system simply energizes a pump to circulate a heated liquid. There are only a few components involved with this preheat invention - making it simple, easy to maintain, and less chance for failure.
Absolutely No Oil Carbonization: With our Hydronic Preheat system, heat energy is exchanged from running hot water through the device to the oil. The oil is brought to and maintained at an optimal atomization temperature with minuet temperature fluctuations prior to combustion. With this method, oil cannot reach a temperature any hotter than the liquid with which it is being heated. With this method of preheating, carbon creation is eliminated because preheat temperature fluctuations are vastly minimized. Whereas oil is vulnerable to carbonization from direct overheating, water is not. Using water to convey heat energy to oil for preheating removes the risk of overheating and carbonizing oil. The water acts as a buffer that absorbs temperature extremes and fluctuations between the heat source and oil.
We use water that is maintained at approximately 80°C (176°F) to preheat oil, minimizing temperature fluctuation. Since the oil's temperature can't exceed the heated liquid's temperature, carbon creation and the removal thereof does not need to be performed. This significant advantage makes this invention much more attractive to the end user.