What do you know about Corn Boilers?

[jimgerken]

With LP costs rising every year, I am getting more interested in buying or building a Corn-fired boiler to be installed in the yard somewhere, fed from a bulk storage bin next to it, and running the heat thru buried insulated water lines (anti-freeze protected) to heat exchangers in the buildings I wish to heat. For instance in the house, it needs only a radiator of sorts for the hot water to flow thru and the air in the cold air return of the present forced air system to pick up the heat. And in my shop I have hydronic radiant floor heat, so it will be even easier to utilize the hot water there. I read last nite that a gallon of LP contains approx 100,000 BTU of heat, and a bushel of dry shelled corn contains approx 500,000 BTU. It is interesting to note that the gallon of LP and the bushel of corn cost about the same in my region right now. But, in other parts of the US, people are paying up to three times as much for LP as I am. It seems that there are also govt grants available to some purchasers of energy products using renewable energy sources, corn soves and boilers included. I think it is economical to install the boiler even without the grants, 'cause according to my math I'd get paid back in about four years. The grants make it sweeter, if they actually exist. And possibly home-building some or all of the system including the boiler would make it seem almost like free energy. I guess it seems attractive since I live in the country surrounded by cornfields, my heating bills rise every year, I can see the bills would be 1/5 as high using corn only, or possibly something like 1/3 as much if it was used only to suppliment my current needs.
Does anyone have info that can help my research into either commercial boilers OR homebuilt ideas? Thanks in advance!

 

[beenthere]

I was thinking you were boiling corn, and curious why that question in January. /forums/images/graemlins/blush.gif
What are you paying for LP? And what can you get corn for? I have heard that low quality (moldy, etc) corn is cheaper and what you want to find to burn. Not sure how long it would take to pay for the investment in the corn boiler, but I would expect it to be several years. Have you some numbers on this projection?

Paying 3 times what I pay for LP would put LP at about $3.75 a gallon. Do you think it is that high?

 

[Birdhunter1]

CORN BOILER, at first I thought (and really hoped) you were talking about a still.

 

[Dozernut]

We have a pellet stove that we really like, the corn stove is not too different. You could probably find a farmer to sell you the corn, but it would most likely be in bulk form(not in a bag). You will need to be able to haul and handle corn that way. You can buy corn bagged and dried at the mill, but you will pay more for it. I was told and read that the BTU content of corn depends on it's moisture content. You could use corn not fit for market if the moisture content is not too high.
I am not too familiar with radiant floor heat, but would a boiler produce too hot of water for that type of system? If I remember correctly, the maximum temp for radiant heat was 120 degrees. Will you be able to keep this low of a temperature with a boiler type system.
Some people make their own heat exchanger for a forced air system. They take a radiator out of a car or truck and circulate the hot water through it and use a fan to extract the heat. A manufactured unit is basically the same thing that fits in the duct works.
These are just some thoughts to mull over, maybe someone who knows more what they are talking about will chime in here and correct my mistakes.

 

[jimgerken]

Assuming the two fuels cost what they cost TODAY, if I switched completly to corn, it would save me $1000 per year. I have heard that the freestanding boilers cost about $3000. If LP goes up to where I hear other parts of the coutry are paying, this savings would be much higher. I read another thread on this TBN where people mentioned paying about $3.75 a gallon, by memory, and even one guy who had to pay $4.50 for a cabin location, if I remember correctly. Yes, the lower grades of corn are even cheaper than the $1.60 / bushel corn. Lighter test weight, older, more fines in it, old seed corn, etc. all will burn.

 

[moeh1]

I have a corn burning stove so the idea works well. My neighbor is set up with an outside wood furnace that heats his house with hot water, and it died awhile ago. I found an outside corn boiler on the net for him that looked awesome, but he went for another wood burner. The one I found used oil to start and for back up if the corn ran out. It had refractory cement kiln inside with alot of water around it, it usually only lit up once a day. Don't remember the brand, think it was made by some boiler guys in the midwest ( where the corn grows /forums/images/graemlins/smile.gif)

 

[gsxr1100]

We got a free Corn stove from my wife’s business (works for Agway). It was a Amaizablaze stove and we then sold it on Ebay. Her boss said they do not burn well in damp or high humidity climates; which MA is. He had 25 stoves and sold them all and will not sell them up here.

We have NG and are staying with it. Not saying NG is better but I need something that burns better, requires no electricity and around here a 50 lb bag is $4 to $5… not worth it.

If I heated my house with corn it would be $4 per bag for 18 hours. That is $160 for one month “if lucky”. I do better then that now with NG (better BTU and efficiently).

Whatever you do get a spread sheet together and look it over!

 

[moeh1]

When I went to get electric service, the company gal asked if I wanted gas service as well. I told her I be tickled pink if they would run gas that far. /forums/images/graemlins/grin.gif After she looked me up ont he map,I'm stuck with few alternatives for heat. Looking at a groundsource heat pump eventually, but for now the corn stove seems to do a good job for me. I get a special deal on corn for $5 a hundred, so its alot better than the retail you quoted. Still,
the outside unit looked nice, but was a monster better suited for a big setup like Jim was looking for.

 

[jimgerken]

I guess my location may be what makes the idea economical. Living in southern Minnesota, I see cornfields everywhere. My Dad still farms and raises corn. There are about 4 grain elevators within 20 miles that would deliver bulk corn to my bin (if I had 200 bushel capacity), for $20 plus $1.50 per bushel (62 pounds). One 200 bushel fill would produce approx the same BTUs of 1000 gallons of LP gas, the amount I use in a winter, plus or minus. 1000 gallons LP at today's retail price would cost $1600. 200 bushels of corn would cost $320 delivered, approx. The savings should pay for a corn burning boiler system inside 4 years, possibly 3. Even if the thing only lasts 6 years, over that time I save about $3000, assuming LP stays at $1.50. However, I am guessing it goes up every year from now on. There's only so much coming out of the earth, and more people and uses every day.

 

[moeh1]

Jim,
you are about 1/4 of retail. Me and my neighbor talked thru the idea with a big local farmer when I was trying to get him set up for corn. The big farmer buys corn - can't plant it, harvest and dry it for what they charge, and it sounds lower out where you are. The boiler I found sounds perfect, I did a quick search, didn't find it again, and the neighbor can't find the literature I got for him. So, regretably, you are on your own. Keep researching, I can't believe you are going to be sorry if you go this route, as long as you get a quality boiler.