Strawhouse Posted August 28, 2014 Share Posted August 28, 2014 Got a question, I am looking at setting up a coal forge in the studio. The studio is setup for metal fabrication but I am just getting into blacksmithing. The problem is that I take up the bottom floor of the studio the top floor is a painting studio for my wife and the roof of the studio is covered in solar panels. The roof itself is a mono-plane pitch ( one single slope ) which faces south for the solar panels. Now the real problem... I need to vent the forge! I cant run a chimney through the roof, and I don't want the chimney pumping smoke out over the solar panels because of soot buildup. I was thinking about building a forge hood with a furnace blower fan inside to suck the exhaust out of the studio through the wall to the outside. The total run of the venting would be about 6' and it would be blowing the exhaust out 20' below the solar panels on the north wall. And don't worry about the neighbours, the closet one is about a 10 minute walk away through the bush and our studio is on 10 acres in the middle of nowhere! So what do you think? Will this work? Quote Link to comment Share on other sites More sharing options...
Glenn Posted August 28, 2014 Share Posted August 28, 2014 Where are you located? It helps get you in touch with other blacksmith gatherings etc Which way does the wind blow in relationship to your building? You will need to exhaust the smoke in such a way it does not blow back onto the building. A chimney extended well above the roof may help.If may want to look into a scrubber. They are not cheap though. Any time the painting studio windows are open, there is a chance of adding some of the aroma and coal smoke to the studio. Ever consider a gas forge? Quote Link to comment Share on other sites More sharing options...
HWooldridge Posted August 28, 2014 Share Posted August 28, 2014 I knew a smith some years ago (he's now deceased) who had a large open shop but didn't want chimneys and stacks all over the place - so he cut a BIG exhaust fan into one side wall (maybe 8'-10' in diameter). It moved a lot of volume and you could feel a slight draft anywhere inside the shop. He could place a forge where it was convenient for the work, light a fire and the smoke would wick up and out. If your forge is permanently located, a nearby exhaust fan should work fine if sized properly. You might also want to consider a TEFC motor so carbon soot doesn't get inside and cause problems. Quote Link to comment Share on other sites More sharing options...
Strawhouse Posted August 28, 2014 Author Share Posted August 28, 2014 Thanks for the response Glenn, The forge would be vented on the north wall which would be the proper side for the majority of the wind that we get here up in Ontario. I have been talking to a few smiths and they are unsure how well it would work. I am actually trying to figure out which type of forge to go with, I understand the ease of propane but I do a lot of art pieces and having the large forge area of a coal forge is something that appeals to me. Good point about the windows upstairs, I guess it will be something that will have to be closed when the forge is running. I just talked to a HVAC guy and he told me that the furnace blower will be more than adequate for sucking up the exhaust... almost too much he warned! DO you think its worth the try? Thanks, The HVAC guy did recommend a belt driven blower and finding a sealed motor. He mentioned it may not be needed but it might extend the life a fair bit. Quote Link to comment Share on other sites More sharing options...
swedefiddle Posted August 28, 2014 Share Posted August 28, 2014 Good Morning Mr. Straw There are quite a few knowledgeable Smiths in the planet, Ontario. Check out OABA, I think they are having a get together this weekend. The knowledge base in Hontario is HUGE. Show your location, There are quite a few who frequent this site. Forget the coal, use natural gas or Propane. It is easy to change the size of a gas forge, by changing the configuration. Don't build the box that curtails your ability to think out loud :) :) Quote Link to comment Share on other sites More sharing options...
Steve Sells Posted August 28, 2014 Share Posted August 28, 2014 I need to mention, at least in the USA, many time a scrubber is not needed, BUT if one choose to install one, for what ever reason it opens a large can of worms. because If you have a scrubber, it must not only have an anual EPA inspection and comply with all federal standards for scrubbers, but the residue it collects is classified haz-mat material and requires haz-mat disposal, neither is cheap. This was a problem for another smith a few years ago, he did not require one, but wanted to be green, lucky he found out about the rules before instillation. Quote Link to comment Share on other sites More sharing options...
Glenn Posted August 28, 2014 Share Posted August 28, 2014 Add charcoal or coke for solid fuel considerations. Good fire maintenance at start up and being careful to eliminate as much smoke as possible during operation, would go a long way to solve the problem. This not a one answer problem. You may have to use several different methods in combination. You WILL have to tweek the system early and often to make sure everything is working at top efficiency. Quote Link to comment Share on other sites More sharing options...
Grant Posted August 28, 2014 Share Posted August 28, 2014 Good morning allstrawhouse, Hofi states that this system is good for a 6' horizontal run.http://www.iforgeiron.com/page/index.html/_/blueprints/uri-hofi-series/bp1048-side-draft-chimney-r175Then see if you need help with the 25' vertical lift. -grantps I can't seem to get this page to link. Go to IFI pages, Uri Hoffi Series, blue print BO1048pss I guess it did link -grant Quote Link to comment Share on other sites More sharing options...
eseemann Posted August 28, 2014 Share Posted August 28, 2014 I need to mention, at least in the USA, many time a scrubber is not needed, BUT if one choose to install one, for what ever reason it opens a large can of worms. because If you have a scrubber, it must not only have an anual EPA inspection and comply with all federal standards for scrubbers, but the residue it collects is classified haz-mat material and requires haz-mat disposal, neither is cheap. This was a problem for another smith a few years ago, he did not require one, but wanted to be green, lucky he found out about the rules before instillation. Steve, Like with an indoor gun range, the cost of the hazmat disposal on the HEPA filters are one of the larger line items. Quote Link to comment Share on other sites More sharing options...
Grant Posted August 28, 2014 Share Posted August 28, 2014 Good morning all.StrawhouseThis is the conjecture part.My shop is in the country, but I do have neighbors. In fact one house is directly downhill from the shop and while they are on board, so far, I would like to clean up the coal forge at start up. To this end I have been thinking about enlisting Frosty’s, and other knowledge person’s, on this form, to help to design a small propane burner and fit it into the stack, this would be used to burn the smoke at start up and one could use it to enhance the draft.This is a taste of what I’m thinking.This air injection system would work for start up if the smoke were hot enough to combust with the additional air blast; I suspect this is not the case. However, this system should work a treat once the forge is up to temp and operating normally; air injection no additional heat source. In fact a version of this was the first emission controls on vehicles in the USA, engine driven air pump plumbed to the exhaust manifold. Any who, this is my rambling for today. -grant Quote Link to comment Share on other sites More sharing options...
Grant Posted August 29, 2014 Share Posted August 29, 2014 I just noticed that the pictures that go with the above link are have either been deleted or the link lost during one of the upgrades to IFI. The link doesn’t make much sense without them. So: Quote Link to comment Share on other sites More sharing options...
Frosty Posted August 29, 2014 Share Posted August 29, 2014 It's been a long time since I saw drawings even but a burner to completely burn the smoke was an option. I don't recall the specifics but I think there was a ring burner with half a dozen flames just inside the stack. Don't quote me on that, it's been a long time and I lost most of my blacksmithing library to a bad associate. What I know worked pretty well when we were coking was to just take a Bernzomatic torch to the pile when it got to smoking to light the smoke. Worked best with a crater punched in the top but once it got smoking good we could light it anywhere. Frosty The Lucky. Quote Link to comment Share on other sites More sharing options...
Grant Posted August 30, 2014 Share Posted August 30, 2014 Good morning allFrost man, thanks for joining in. Yes, there have been times that the judicious use of the weed burner aided the transition and it’s not to say that with more coke on hand and gentle fire management the problem could be not mitigated. But it is enjoyable to speculate.My initial thoughts are that a burner and air blast would be introduced into the stack. The burner would initially be used to warm the stack and burn the excess smoke during start up. Once a stable forge fire is achieved the fuel part of the burner would be shut down leaving the air blast to complete the combustion of the smaller particulates and Bob’s your Uncle. -grant Quote Link to comment Share on other sites More sharing options...
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