Frequently Asked Questions
Converting to Wood-Fired Heating

Cost Savings

How much can I save?

Converting to wood fuel has shown savings of up to 100% of a company’s current heating costs. Since heating needs are dependent on building size, ceiling height, door-opening requirements, desired inside temperature and air make-up, savings will vary. The actual projected savings are often significant. We recommend you call us for an individual assessment. If you would like to speak to someone who has experienced such savings in your industry, we are happy to provide you with a contact.

Do I need on-site wood residue to make the BCS Shop Heater cost-effective?

Certainly having the wood residue on-site is an ideal application for a wood-fired Shop Heater- fuel is virtually cost-free. But with oil prices continuing to escalate, an external source of wood fuel may also prove to be cost-effective.

How is this system efficient?

The key to efficient combustion or heat production is exposing these released gases to high temperatures, optimally, for an extended period of time while continually mixing the gases with oxygen. The true test for successful, efficient combustion is the consumption of all these gases as evidenced by the lack of smoke. Smoke is simply unburned gases and particulate and its presence indicates a system that is not operating an efficient combustion process.

The BCS Shop Heater After Burner Chamber design creates the environment for the ideal combustion process. In the main chamber, wood gases are released and are then drawn through the After Burner Chamber for maximum combustion. The narrow, hot chamber creates a concentrated high temperature for an extended period of time while maintaining a constant flow of oxygen to mix with the gases. Unlike traditional wood burners, this represents a multi-stage, thorough combustion process. For users, it ensures a system that converts all of the wood to a viable heating fuel and eliminates smoke.

Shop Heater Engineering and Durability

How long will the burners last?

Since its design in 1985, many of the original systems are still in service. These all-steel Shop Heaters have been built with ruggedness and longevity in mind. The 36” firebox is reinforced with 3/4” steel end plates to withstand repeated wood loading, unlike refractory fireboxes which are subject to potential cracking, creosote build-up and therefore increased maintenance.

Additionally, the unique “cylindrical” firebox contributes to its durability. Stress from the natural contraction and expansion caused by repeated heating and cooling is equally distributed around the cylindrical design. Whereas, a rectangular firebox is susceptible to increased stress and cracks on their welded corners.

System Operation

How frequently do I need to load the Shop Heater?

This depends largely on the moisture content and particle size of your wood. The lower the moisture content the better, so large dry blocks will produce the most heat for the longest time. Most people load their burners between five and eight times over an eight hour day.

How long does it take to load a Shop Heater?

Less than five minutes! Again, we are prepared to connect you with existing customers in similar businesses to yours to get a first hand account of the BCS system’s ease of operation.

I intend to have this in my shop; will smoke come into my plant while it is being loaded?

No, the burner is engineered to eliminate this possibility. An induced draft fan located at the top of the system puts the firebox under negative pressure. Consequently, when the door is opened for loading, air is pulled into the firebox which prevents smoke from escaping.

How do I regulate the heat coming from the burner?

The system is equipped with two separate external hand valves for heat regulation that control over fire and under fire air flow. The over fire air valve is calibrated during installation to maximize the wood fuel being burned. The under fire air valve is simply the fire’s throttle. Just like a regular wood stove, the BCS Shop Heater can be turned up or down by the amount of air allowed under the fire.

Are there other monitoring devices?

For daily management, the Firebox Temperature Monitor displays temperature to conveniently check on fuel-loading needs. This unit also keeps track of the stack temperature, an indicator of when the heat exchanger needs to be cleaned.

To conserve electricity, a thermostat monitors the air temperature flowing through the system. When the air cools below an acceptable temperature (on weekends or nights), the fan automatically turns off to prevent cool air being circulated and from using unnecessary electricity.

Our operation requires an air make-up system; can this Shop Heater be used for air make-up?

Absolutely. The Shop Heater is used to replace air that is pulled out of the plant by a dust collection system or spray booth. Simply allow outside air into the Shop Heater room and it will be pulled through the burner by the high volume, 9000 CFM distribution fan. The hot air directly replaces the air loss from the dust collection or spray booth exhaust fans. Please contact us for more detailed installation instructions.

Maintenance

What are the maintenance requirements?

About once a week (generally on Monday morning when the burner is cool) ash will need to be shoveled out the front door. This ash can be placed in a 55-gallon drum and hauled away to a landfill after it has cooled. In addition, the heat exchanger will need to be cleaned every few weeks to maintain efficient heat transfer to your building. To make this job easier, BCS provides easy-access doors above the firebox loading door and a properly sized brush which fits on a ½” drill. The drill spins the brush as the operator pushes it through the heat exchanger tubes. This tube cleaning should not take more than ½ hour. It is also recommended that ash be removed from the back of the heat exchanger twice per heating season. The heat exchanger is also accessible for cleaning through access ports.

Installation

What resources do I need for a successful installation?

Most users do their own installation with the detailed installation manual that comes with the system.

Does it need a separate furnace room?

Not often, over 80% our BCS Shop Heater users are on the plant floor. However, it is worthwhile to check your own state’s regulations.

Environmental Impact

Will this Shop Heater put smoke out the stack?

Smoke is simply unburned gases and particulate. A minimal amount of smoke may be emitted during start up, but once up-to-temperature the system will not smoke if operated properly. This clean-burning, smoke-free system is also representative of exceptional wood burning efficiency. By burning these gases and particulates in the firebox, the system optimizes the heating value of the wood fuel. All that should be seen coming out of the stack may be water vapor from the moisture in the wood, therefore, no wasted fuel.

Do I need a special permit to operate?

Most of our installed systems have not required permits. As regulations are state-specific, we recommend you contact your local air quality office. Be sure to indicate that these Shop Heaters are under a million BTU/hr input and will only be burning clean wood.

Is burning wood harmful to the environment?

No, in fact, wood is a renewable resource which environmentalists consider carbon “neutral” because trees absorb the carbon released when wood is burned. Carbon emissions from fossil fuels, such as oil and gas, are a major contributor to ozone-depleting greenhouse gases. So fossil fuels add carbon to the atmosphere while wood energy recycles carbon. In addition, unlike oil and gas, wood does not emit sulfur which contributes to acid rain. When burned efficiently, you can feel good about using wood fuel.

Please call us at 508-798-5970 or email us at info@biomasscombustion.com , if you have additional questions