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I) Parts List:
Reactor: - Reactor outs ide ves s el tube - Bottom end plate - Top flange ring - 1/2" 90deg plumbing elbows (5 count) - 1/2 npt to 15/16 gas flare adapters (5 count) Air Nozzles: - 1" x 7.25" nozzle tubes (5 count) - 3/8" s treet elbows (5 count) Reactor Lid: - Lid plate and parts - Inner reactor ves s el individual parts
Note: This could be said to be the core element of the GEK, and involves the most complicated fabrication of the various GEK parts. Pay careful attention to all instructions, and make sure you
complete each step before doing the next one- there are many build order dependencies. II) Construct Reactor Lid
Orientation: The threads on the weld s tuds and the couplers will be on the top of the lid. Weld: air tight. Clamp lid plate to a fabrication table or thicker plate of s teel, all the way around with at leas t 6 clamps . Make s ure it is s ecure, this plate in particular loves to warp from welding heat. Fit (2) 1.5" halved couplers over appropriate holes , tack in place. Tolerances: Find the s maller cover plate lid that fits over the larger opening. Make s ure the welds for the middle 1.5 in halved coupler clears this lid plate. Make 1/2" s titch welds around the couplers , alternating s ides around the couplers and allowing plenty of cooling time between welds . Take your time with this part. Again, it jus t loves to warp into a potato chip s hape. Remove clamps and fit 5/16 weld s tuds through with the threads facing through the top of the lid, place cover plate lid over bolts and tighten down with nuts . Weld bolt heads with air tight weld.
III) Reactor:
A. Reactor Vessel: Weld flange ring onto reactor vessel tube Orientation: This ring is toward the top of the reactor. Us e any tab and s lot pos ition. Center your s tarting tab in the middle of the corres ponding hole. Make s ure tabs are pulled all the way into s lots with C clamps . Us e C clamps as you weld around circle. We've had the bes t res ults with extra deep throat C clamps and a s mall homemade "pi s ymbol" s haped clamp helper, s een in many of thes e photos , the intervention of which provides a flat s urface on flange edges for the clamp foot to s it. Weld: Tack the flange ring to the reactor ves s el tube.
Orientation: The bottom plate of the reactor s hould match up with the bolt and cut pattern of the hourglas s bell. The face that mates correctly with the hourglas s bell is cons idered the 'top' or 'ins ide' of the reactor.
Secure the bottom flange plate with the top facing ins ide the reactor ves s el. Line up the notches in the flange plate with the reactor wall. Make s ure this s urface is flat with an air tight weld.
Make s ure the s eam is even down the length of the reactor ves s el and tack in place.
(*picture from earlier vers ion) For the top flange for the reactor, clamp to make s ure the flange is s quare and tack into plate underneath the flange plate. Do not weld on the top/inside the flange plate (this flange plate will mate with the lid to ensure a good seal). Do not apply larger tacks or fully weld this connection, the air neck will need to inters ect at this point later on. B. Weld 1/2" 90 deg elbows into bottom flange end plate You might need to grind off cas ting debris on the elbows to get them to fit through the holes in the bottom end plate. If you need to, do NOT grind off the collar as this collar is us ed for offs et s pacing during the fabrication below. Find the air lines , note that thes e air lines will s crew into thes e 90s on the bottom of the reactor. Make s ure that the edges of the air line fitting will clear the reactor and welds .
Align elbows and weld them into bottom flange end plate On Bottom (bottom view): Elbows s hould radiate outward to the left. The air lines s piral outwards clockwis e, pas s ing as clos e as pos s ible to the next air inlet tube as they radiate outward. Thus the elbow s hould be aligned s o that the air line will pas s jus t to the s ide of the next elbow. See pictures at http://allpowerlabs .org/gas ification/gek/images /v1.0/reactor3-800.jpg for clarification. The collar on the elbow s hould s it on the bottom end plate. Do NOT grind off the collar, as this s pacing is needed s o there is room to s crew in the s tainles s s teel tubes . Do NOT pos ition the elbow further out or it will obs truct the grate when ins erted into the gas cowling. Ins ide Reactor. The elbows need to be aligned s o the air inlet nipples ris e s traight upwards and parallel with the ins ulation ves s el tube wall. You can us e a right angle to draw s traight vertical lines up the ins ide for alignment. Then us e a 12" or s o 1/2" pipe nipple with a coupler on the end to s ign to this line. Pus h the elbow and the coupler up agains t the wall to ens ure parallel orientation to the wall. A combination s quare will as s is t with vertical alignment. The line and the coupler/elbow collars are your jig alignment tools . Us e a clamp to hold the jig in place. The elbows need to be welded in gas tight. It is eas y to mis s s pots around the neck of the elbow.
H. Stitch Weld Around the Air Neck, Alternating Top and Bottom Edges
We've us ed 2"-3" welds at a cooler s etting, making a weld on the mid flange/airneck s eam, and then alternating to the mid flange/top flange s eam, leaving 2"-3" unwelded s paces between them as we go. This dis tributes heat and allows s ome cooling as you go around. See photos . The 3/32"-1/8" gap above the airneck and beneath the top flange s hould become fully filled with weld bead as you go. Both of thes e s eams need to be good and airtight for proper functioning of your GEK! Keep rotating the ves s el, filling and alternating s titches until both of thes e s eams are fully welded Weld vertical airneck s eam When fully welded, s et as ide and let cool. Do not remove bolts until it has had a chance to cool off!