GEK Wiki / Fabrication Instructions
  • If you are citizen of an European Union member nation, you may not use this service unless you are at least 16 years old.

  • You already know Dokkio is an AI-powered assistant to organize & manage your digital files & messages. Very soon, Dokkio will support Outlook as well as One Drive. Check it out today!

View
 

Fabrication Instructions

This version was saved 15 years, 3 months ago View current version     Page history
Saved by jim mason
on December 19, 2008 at 6:08:49 pm
 

How to Build your GEK

 

Here are the complete instructions for fabricating all components of the v2.0 GEK gasifier system.  These instructions assume you have a Level III kit and thus are in possession of the needed sheet metal, plumbing and accessory parts.  If you have a Level II sheetmetal only kit, you'll need to acquire the following plumbing and accessory parts.  If you are trying to do this the hard way and build from scrap obtainium, you should use the drawings on the downloads page to produce the raw sheetmetal parts before "reinterpreting" the instructions below for fabrication.

 

The GEK gasifier system consists of the following seven components.  We will build each of these components separately, then bolt them together for the integrated unit.

 

Gas making:

     1. Gas cowling and ash handling outer vessel

     2. Downdraft reactor which inserts into the gas cowling / ash handling vessel

     3. Fuel hopper which can bolt on top of the reactor

 

Particulate clean-up:

     4. Cyclone to separate large particulates from the gas stream

     5. Packed bed filter to separate small particulates from the gas stream

 

Gas combustion:

     6. Centrifugal vac/blower

     7. Swirl burner 

 

Once you have built all the components using the fabrication instructions below, you will use the final Assembly Instructions for how to put it all together and prepare it for running.

 

 

Fabrication Method and Standards

 

All GEK vessels are fabricated using the same three basic part types: vessel tubes, flange rings, and end plates.  Flange rings and end plates are welded on the ends of the cylindrical vessel tubes.  Flange rings are usually at the top of a vessel tube, and fit around the outside of the tube.  End Plates are usually at the bottom of a vessel tube, and fit inside the tube.

 

In all vessels, the circular plates/rings function as the jigs to pull the vessel tubes to perfectly round for welding.  Tabs and slots on all vessels simularly index the pieces together and ensure an accurate finished product.  This system of “self-jigging” is central to the ease of building the GEK.

 

While following the step-by-step instructions below, be sure to remember these other common standards across the kit.

- All flange rings and end plates should be oriented such that the slag side is down.  (note: Oct GEK run needs the reactor bottom plate flipped so slag side up.  we made a mistake on this one)

- All vessel tubes are rolled such that the slag side is facing inward

- All vessel tube seams should be in the rear center of the vessel

- All large vessel tubes will have approximately 3/8" overlap at the seam joint.  This makes welding much easier than welding sheet edge to edge.  The smaller vessels (cyclone and swirl burner) will have 1/4" overlap at the seam

- Tabs and slots will give you the correct positioning.  But do be careful to center the first tab and slot so the others will come out correct.  See notes in below text for details.

- When welding flange rings and end plates, start with short stitches around the circle.  Do not do one long continuous weld or you will warp the flange. 

 

Once you've built all the components listed below, you can proceed on to Level IV Assembly Instructions for how to put them all together into a functioning unit. Painting the outsides of most of these components is a good weatherproofing measure, but pay very close attention to the photos in Level IV Assembly for what to paint and what NOT to paint- paint in the wrong places can burn, create mess and toxic fumes.

 

And finally, here are the step-by-step instructions.  We encourage you to build the components in the order presented below.   Also, following the order of individual instructions will keep you away from annoying critical path issues.  Yes, we realize instructions are annoying in themselves, but they are always less annoying than unwelding the wrongly welded . . .

 

 

Gas Cowling and Rotary Grate

 

Downdraft Reactor

    

Cyclone

  

Packed Bed Filter

 

Axial Fan

 

Swirl Burner 

 

Hopper

 

 

 

 

Comments (0)

You don't have permission to comment on this page.