[Solved] PROEKO PLUS Boiler & Blower Issue: Airflow Problem, Nozzles, Proton PID Controller & Fixes

Hello, honorable forum members.

Please help. Maybe someone will have an idea for my situation.

I will use specific links, and to be clear, but this is not an advertisement - I note.

I bought a PROEKO PLUS boiler from this link http://www.kotly-witkowski.pl/kotly/proeko-plus

In addition, I bought a supposed to be very good in bags from this link https://ekogroszekprestige.pl/mial-weglowy-pakowany/

Unfortunately, after some time I realized that this boiler is not 100% fine. It has an airflow only from the ash pan and only on one side. It has no nozzles in the charging chamber. The air from the fan does not pass through the fuel. I light up from above. Proton PID controller.

In connection with the above, I have made a RHS profile with holes drilled from the bottom up. Length is about 0.5m long. Blinded from above. I put it in the middle of the grate. Air is leaking now. On top of the fine coal I put some coal on the fire. It burns like stupid, but when the coal burns out, the dust does not give much heat. Problem with reaching the set temperature. In fact, it barely heats the stove itself (I set the pump to turn off around the set temperature). As if there was too much air (cooling with blowing). As if there were no calories in fuel. You can't see the blue flames.
I am asking for some ideas from experienced smokers. What can I do here. I bought the cauldron for my in-laws. I bought them had and thought that this species would be a rocket, and here my hands drop. I'm in dead end. Boiler 11KW. The manual says that from about 16KW there are nozzles on the back wall of the hearth. I didn't know about it. I'm in a bind of what to do. I've never smoked. I am asking for some help. Thank you in advance.

piloszkotosz wrote:

it did not give much heat.

Because he had it. It is low in calories by nature, unfortunately. Anyway, I am surprised by the description of this fine coal: "crushed high-energy coal" - they crushed good quality coal (which is by nature expensive) and sell it as much cheaper had? I don't feel like believing in it ...

piloszkotosz wrote:

Problem with reaching the set temperature.

Or maybe the boiler is too small for the needs of the building? As far as I know, the power of the fine coal boiler is selected differently than that of other solid fuel boilers:
http://czysteogarzenia.pl/kociol/co-za-duzo-t...kotla-weglowego/#Wyjatek_dla_kotlow_mialowych

Thank you for your participation in the topic.
The boiler is ok when it comes to power. It drives 4 radiators and 80l hot water. The radiators are not big.

One week I decided what to buy and unfortunately it fell on this one. I did not notice that the smaller model has airflow only under the grate. When I put in eco-pea coal, it warms up too much. The pipe with holes allowed any smoking. Without it, it went out upstairs. But I'm not sure if I did it right, and I found no descriptions anywhere except for one video https://www.youtube.com/watch?v=7wWxIncrlr4

I blinded from the top because all the air would have escaped. You could mix with a thicker one, but the in-laws took 3 tons at once and I was left with the problem. Horror.

piloszkotosz wrote:

You could mix with the thicker

I just wanted to write this. The had you smoke is just too tight. Perform a firing up with 25% fines compared to what you poured at the beginning. If it burns well, with each new fire, increase the height of the charge.

Thank you Magister_123
I just brought a bag of coal dust for the test, which was burned in a DRAGON type furnace. It burned very well and purple. Only this one
the boiler has two inlets for the grate on the left and right and a few holes on the sides in the walls
charging chamber. I'll let you know about the effects. Greetings to the forum members.

Added after 4 [hours] 2 [minutes]:

If I write a post under my post, sorry, but I rarely write something on forums and I'm not very experienced in it.
So I'm writing about the effects. I fired the RHS which I put in the center of the grate. He failed the exam. because it burned out near him and nothing towards the walls of the chamber. I dumped 2/3 of the furnace dust and the rest of the ash. After thinking about the subject, I cut 4 pieces of 1 "pipe and cut one side with a flex at a sharp angle. Thanks to this, they fit firmly and tightly into the grate. I placed them in the four corners of the boiler.
There, they block and take the air blown under the grate. Of course, drilled 7-8 every 7-8 cm. The higher the gaps are. Holes directed to the center of the charging chamber. At the top, they are tied with four slightly welded rebars, so that they do not break apart.
And in order to eliminate at least one of the factors, I lit it with a bag of fine coal that was delivered and checked. And now the effects.
It burns like a gas stove . It burns on the entire square surface from the center to the sides. The stove jumps 2 degrees up and down and heats very reliably and smokelessly. I am currently very busy after all this (additionally I have a renovation which I do myself), but I will try to post photos and videos of this case as soon as possible. Maybe it will help others in a similar situation.
If I knew it would be like that, I would have made 4 thick-walled flat bars with pre-drilled holes right away and caught on the corners. Those that would protrude a little above the lower edge of the hopper and take air from the sub-grid. This is a test for the moment, so maybe I'll do it before the boiler overgrows.

The next stage will be ignition on "super fine coal" :lol:

If it's not ok, then it's a complaint. For now, thank you for contributing to the topic.

I will post the materials. Best regards.

Added after 19 [hours] 46 [minutes]:

Welcome back.
Well, it's been burning for about 20 hours. 2/3 of the load is left. All the time the flames are all blue. Maybe if I added 4 more tubes in the middle of the coat, the aeration would be around and even better, but maybe not overcomplicating it ???.
Tomorrow I will try to post photos and videos. Best regards.

So I'm adding photos of the smoking process.

The first patent that did not work completely, i.e. the rhs in the middle of the hearth:





Before that, I put paper on the fire, but it turned out to be wrong. It also blocked the flow. Now first 5 cm of eco-pea coal



For this, he had 5 cm of eco-pea coal at the top and a fire



This is what it looks like after an hour



If I find out how videos are added, I will attach it.

Generally it burned for 30 hours. This is what the patent looks like. You can basically set it up and not weld, because I didn't move anything in the chamber after that. When removing ash, you can freely remove it for cleaning and reinsert it. Burned ones are easy to replace. More tubes can be added at any time. I have one more batch of good fines, so I will describe the tests with this "great" in 4-5 days.



I also plan to put a deflector, e.g. made of fireclay bricks, on these bars, when the load is slightly lower. Plus, maybe I'll make swirls between languages. I will be adding information slowly.

Generally, a very easy method for all those who have similar boilers only with air from the bottom, or even typical fine coal, but want to improve something in half an hour without welding, etc ...

I am asking for any comments and opinions, and if it helped someone, maybe a point .

piloszkotosz wrote:

If I find out how videos are added, I will attach it.

You click "reply" at the bottom of the page and when the page opens, you have the "add movie" tab above the text field. You click and follow the instructions.

piloszkotosz wrote:

I am asking for any comments and opinions

If it helps and you do not need to weld anything on the boiler, then I am absolutely in favor of such a solution. It generally looks like a furnace chamber ventilation system in a fine fine coal construction. The only difference is that there are ventilation holes along the entire length of the side wall, not just at the corners of the hearth.

piloszkotosz wrote:

I still plan to put a deflector, e.g. made of fireclay bricks, put it on these rods, when the load is slightly lower

And how will you solve the deflector to maintain a constant distance from the charge as the coal burns off?

piloszkotosz wrote:

and if it helped someone, maybe some point

You already have it from me - for the ingenuity and simplicity of the solution.

Thanks to Xantix for the positive feedback.

As for the deflector, I have no idea how to adjust the gap, but I think that the addition itself should bring some positive effect. All in all, with the door closed and the heat there is high temperature and when the deflector heats up, it has to burn out a bit, but that's just my opinion.
You write well about more holes in fine fines. I got the idea that you can make such side attachments from sheet metal. Two plates with the width and height of the side wall from the charging chamber, or slightly lower. They would be e.g. 1-2 cm apart. The sides and top are closed with flat bars. Open bottom and located along the extreme grate. Structure adjacent to the boiler wall. There are holes in the outer plate adjacent to the fuel. The air from under the grate would come inside and it would provide great aeration. The second same structure for the second wall. You can and all of them. The question remains how large the structure will enter through the door (different furnaces). If I do a little, I will do it and test it.

By the way, I used to make some kettles for my friends when I was younger and had a little more strength and time. They were for wood and heating oil, and various, with and without a feeder. Hence a bit of ingenuity.
I made the last boiler three years for myself after a long break. It burns completely smokeless coal. It has a fireclay burner, a vizier tube and patents like that.
Maybe when there will be a moment, I will create a topic and present photos and descriptions.
There are also people who want to do something for themselves and will probably benefit from something. Best regards.

After firing up

[movie: 491ad2d54f] https://filmy.elektroda.pl/41_1540200479.mp4 [/ movie: 491ad2d54f]

Some time after firing up. Sorry for the audio, but I don't have time to edit the video.


[movie: 491ad2d54f] https://filmy.elektroda.pl/52_1540200690.mp4 [/ movie: 491ad2d54f]

Added after 40 [minutes]:

I wanted to add a little sketch as if I would see it more or less.



Sorry for the scribbles

piloszkotosz wrote:

Well, it's been burning for about 20 hours. 2/3 of the load is left.

How many kg did you put the fines into the chamber?

I covered the incomplete 25 kg bag of fine dust. Some peas down and up, but not much.
After 30 hours the temperature was starting to drop, so I turned it off. It burned out to the very grate almost. When I come back from work, after 5 p.m. I will fire up again.

The post-German home of my parents-in-law is said to be 160 years old. Pruchno and clay with bricks. Not insulated. He heated four radiators and a boiler.

In terms of better combustion, I thought that the last holes from the top, or the last 2, should be drilled at an angle. Then a vortex will be created and air will be better mixed with the combustible gases.

It turns out that you smoke with an average power of about 6 kW. There is about 20 kW in the film when firing up. In my opinion, unfortunately, with such a low power, you will not have a better afterburning ... with such a chamber. But don't give up, maybe you'll come up with something ...

Hello.
The boiler always runs at much higher power when firing up, because the water is cooled down. The controller gives max. airflow (which I just set) and then the PID catches up with the setting. I have a hysteresis of 5 degrees and at minus 5 degrees from the setting, it starts to slow down. When it is -2 to the current setting, it spins slowly.
With time, when everything warms up, the boiler only "cracks" and gives only as much power as needed to maintain the set temperature. This is how it should be and normal. With this afterburning of exhaust gases, it is about savings - you know. But it's more about cleanliness in the boiler and chimney. I'm not going to run from my stove to my in-laws and scratch and I don't think anyone likes it. As you can see in the attached materials, the combustion is very good and there will be no major savings here. Do not kid yourself. But the fewer unburned exhaust gases, the less cleaning, that's why I fine-tune this topic. Besides, this is my horse and so I already have that if I can improve something else, I will not give up. Best regards.

But I know all this, only afterburning of exhaust gases is contrary to flammability, I am not able to achieve clean combustion below 6 kW, which, as I look at the furnace after firing up, is yours, so in this situation the swirlers will not help, you will have to increase the current boiler power which will lower the flammability.

The cleanliness of the boiler depends on the cleanliness of the combustion itself, from the ignition itself, the flame is not clean during the ignition.

Here you have a look at my experiences. https://www.elektroda.pl/rtvforum/topic3298994.html#16933797

Hello Sstalone.
I agree with you. You will need to scrape it from time to time, or heat it well and clean it. There are no miracles. But if we didn't do anything, it would be overwhelmed. We're not going to make a doctorate out of it anyway . If it was my cauldron, I would put some fireclay on it and thus reduce the surface of the "burner". I would light up more often, but the boiler would run at higher speed (because less power) and it would burn even better, but I don't have time to play and it will stay that way. The in-laws are taken to heaven anyway, and because they are over 80 years old, it helped them a lot. After work, I will choose and clean the next batch. I have 30 hours of rest. I'm glad it ended this way, because I was in a slight panic at the beginning. But I will make these records in my spare time out of curiosity. Regards and thanks for participating in the topic.

Hello, after a little break.
I must say that so far, I have a significant problem with smoking, I had a great one. There is basically no flame above it. Day to night compared to the one transported loose from the square. I do not know if it is the fault of insufficient aeration or such fuel.
I have a question for col. Sstalone, which I had smoked or smoked. Whether you soaked or completely dry. I have read a lot about it and opinions are divided, but looking at your clean exchanger and the quality of smoking I am full of admiration. I have no experience with such fuel. Mine is very dry to the touch. I think I got too wet the first time. It burned poorly. The second time I got wet so that light sparks flew. Effect to + None. I have already written to the consumer ombudsman and am waiting for a reply. I don't know how it will end. Best regards.

In retrospect, I have mastered the topic of smoking and close this discussion for the sake of order. Greetings to the forum members.