High-Performance HeatGreen Home Heating System Version 3a

This "active" version of the HeatGreen system has great flexibility and sufficient capability for nearly any residential heating application. It is absolutely "green" and eliminates the need for any buying or using of any fossil fuels.

The relatively small device described here (roughly the size of an upright piano and weighing empty around 140 pounds) (and with all construction instructions included below) is around 5 feet in diameter and 2 feet thick. It can easily create the continuous 45,000 Btus per hour of constant heating that a medium-sized home in a cold climate like Chicago needs in January or February, and has shown that it can easily produce twice that amount of heat, or over 90,000 Btus of hour.

This presentation is primarily centered on describing how to build this HG 3a unit with around $200 of locally available materials. Since there are a wide range of climates in the world, and sizes and types of homes, and an immense number of different ways this device can be used, we will include an assortment of simple calculations and explanations, such that each locality or each person could modify the standard HG 3a unit for specific needs. If you want to learn more about how and why the HG heating systems work so well, the presentation at General Description may be useful. That presentation also has a link to a more comprehensive presentation which includes the Biochemistry and Thermodynamics aspects, which we think most people do not want to have to confront!

As noted above, the standard HG 3a unit is relatively modest in size, for several reasons. It is designed to be light enough when empty (140 pounds or so) to easily be carried (or rolled!). It is designed to be of dimensions where standard-sized pieces of plywood are very efficiently used with very little waste, and also so that it can fit through standard doorways. It also is designed so that when completely filled, it does not weigh much more than a filled food freezer, and therefore will not stress building floor structures. The dimensions provide an inside capacity of around 40 cubic feet, so depending on the density of the organic material used, around 400 pounds (at 10 pounds per cubic foot dry density) to 800 pounds (at 20 lb/cu ft) of material usually can be put into it at a time. (Certain materials like sawdust or feed corn are of higher density and greater amounts can be loaded at a time.)

If we consider the most conservative value of 400 pounds of material being placed in it, here are two common possibilities that can happen.

Both of these scenarios are describing the performance of the very SMALL version of the device, the HG 3a, described below. They tend to require a good deal of time and effort regarding loading material. Long ago, people used to load coal in a furnace to heat their homes, and it turns out that roughly the same total amount of weight of organic material needs to be loaded here as was done then. We note that there were companies and individuals who were available (for payment) to load the coal in those furnaces so the homeowner did not have any inconvenience, and that seems possible again with this HG 3a device.

It is certainly possible to make larger scale versions of this (which will then no longer fit through a standard doorway). One that is twice the dimensions could hold eight times as much material, or around 3200 pounds. Still at a decomposition rate of 5 pounds per hour (during January or February in a northern climate), that is full heat for about 640 hours or about 27 days of whole house heating before a new load of organic material needs to be loaded in it. Keep in mind that the building floor structure would then have to be able to support roughly the weight of a car, and the ceiling would need to be around 12 feet high for that particular size and shape! But the same diameter as a standard HG 3a could be made but twice as thick, etc, to increase the capacity. There are some structural considerations when such changes are made, such as stiffeners, which may be needed.


This HG 3a design also has the built-in capability of providing large amounts of domestic hot water. The arrangement described below can contain either 8 gallons or 14 gallons (of around 150ºF water), which can fully heat up from a standard municipal cold water supply in roughly 15 minutes, which can therefore provide a virtually endless supply of hot water for bathtubs or clothes washing. (A full bathtub of wonderfully hot water at fifteen minute intervals for all the kids you have!) (Or all the hot water needed for full loads of a clothes washing machine every fifteen minutes.) The water heating performance of the configuration described below is around 24,000 Btu/hr to 27,000 Btu/hr, reasonably comparable with conventional hot water heaters (which are often rated somewhat higher at the INPUT amount of natural gas consumed). It can easily be increased or decreased depending on the size of your family.

Cooking inside it seems to be an interesting ability, although there seems to be a slight complication due to the very slow tumbling of the device! The cooking action resembles a Crockpot or Slow-Cooker regarding the wonderful taste of the results, but also the time required. This capability requires a modification of the device's door structure, but it nicely cooks hamburgers and many other foods, although the 150ºF available temperature requires longer cooking times than on a stovetop. For example, hard-boiled eggs needs about two and a half hours to be fully done, but they seem to me to be even tastier than normal HB eggs, more delicate, possibly due to not needing the boiling water. In my opinion, cooked sweet corn (45 to 60 minutes) is more tender and delicious than when cooked in other ways. When the corn is cooked while still in the husk, it probably maintains all the natural vitamins as well, which get lost in standard cooking methods. The same seems to be true of other vegetables, possibly because I do not use water for any of those functions. It also does seem to virtually not matter how long the eggs, corn, vegetables or hamburgers are left in the cooker, as even after 12 hours my experiments have all been delicious! This method of cooking is absolutely safe, possibly even more so than conventional cooking, as ALL dangerous pathogens are easily killed at these temperatures, as long as the food rises to above 125ºF. With conventional cooking, sometimes the center of a thick piece of meat does not get up above that necessary 125ºF, where people can then still have E. coli and other pathogens still present in the meat. That is not possible here. However, "Rare" may not be a possibility, as the low heat for a long time penetrates completely through even thick items of food.

I have discovered that it also can brew amazingly tasty coffee and tea, similar to how "sun tea" is made that is so tasty! But where sun tea is generally rather weak, this system brews tea or coffee that is of conventional strength of taste. There is no harshness in the taste, really amazing.

(Sorry about these tangential comments from the heating system, but new and different uses seem to keep appearing for it!)


(As a side note, many house furnaces are rated at 125,000 Btu/hr or so. That is actually INPUT energy rating, the amount of natural gas burned, for example, where some of the created heat goes up the chimney, leaving a maximum of around 100,000 Btu/hr of actual heat which could be available for the house. Conventional furnaces are designed so that their burner should be on 2/3 of the time when the outdoor temperature is the Design Temperature for that climate [ which is -10ºF or -23ºC for the Chicago area ]. This means that that 125,000 Btu/hour (input) conventional furnace really is intended to provide a MAXIMUM of around 67,000 Btu/hr of constant heat supply on the coldest night of the year. Generally, calculations for a well-insulated house near Chicago shows that the design heat loss is around 40,000 to 50,000 Btu/hr AVERAGE on that coldest day. This is why we are discussing heat productions of 45,000 Btu/hr as being sufficient and 90,000 Btu/hr as being too much heat!)

This 3a Version appears to have some major advantages. Several are due to the fact that the entire drum "tumbles" every hour or so. It move so slowly that it is hard to even notice that it is moving at all! The decomposing material inside does not "clump up" as some types of materials can tend to do over the time of the decomposition. This tumbling also allows more free access of the oxygen to all the material, which is why it is capable of such fast performance. Even the supply (puddle) of several gallons of excess water that we keep in the bottom tends to get stirred together with all the material, ensuring that all material has sufficient moisture available for good decomposition, again enhancing performance. Plenty of oxygen and plenty of water available to each tiny thermophilic bacterium! They love it! As a result, they decompose virtually anything that is organic very quickly. (Some types of material take longer, such as used car tires or used motor oil or most types of plastic or thick pieces of wood.) Another advantage is that the drum rotation could be slowed to once per day instead of once per hour, which degrades the performance somewhat for lower heat production, by nicely slowing down the rate of consumption of the material when less heat is needed for the house. (Slower decomposing material, such as straw, can also be used to cause less heat production.)

This (small) Version of the HeatGreen home heating system is capable of producing all the heat you could want, but it also can consume the organic materials you put into it very rapidly, but only because its capacity is so small! That means that this small system CAN provide all the heat necessary to entirely heat a moderate-sized house in the worst of the winter, BUT for only two or three days before it would need to again be filled with another 400 pounds of material! This seems rather labor-intensive, and so we also mention a larger-scale Version of this rotating HeatGreen system.

You will build a device that resembles a large exercise wheel for a hamster. Or a Galapagos Tortoise, as it is very slow moving. We will describe one that is about five feet in diameter and two feet thick, such that it can be carried through standard doorways. As noted above, that size has an internal volume of around 40 cubic feet. At a density of the organic material put into it of 10 pounds per cubic foot, that means around 400 pounds of organic material will be present to decompose, which will give off a total of around 3,500,000 Btus of heat energy during that decomposition process. (Some organic materials are more compact than that, such as feed corn, where more weight of material can be put in it at a time.

(These are simple and inexpensive enough to build, requiring only around $200 of materials from a local store, that it could make sense to build two of them for your house. You would schedule loading material in them at different times, so that the two days while the process is beginning would not be a problem, as the other one would be fully heating the house for those two days. Also, if your water supply or air supply to one of them was interrupted, the other one could still be comfortably heating your house.)

Parts Materials

(Prices shown are retail prices in Dec 2007 from a home supply store)

FunctionQuantityItemRetail Cost
Main Structure Sidewalls2 sheets of 3/4" thick GOOD QUALITY CDX plywood, of 5- or 7-plies. $21.44 * 2 = $42.88
Main Structure Perimeter1 sheet of 1/4" thick plywood.$13.88
Side Insulation4 2" thick or 8 1" thick sheets of 4x8' foam building insulation, 2" or 1" thick, either interior (white) or exterior (underground). either $6.49 each for interior 1" or $12.29 for exterior 1" each. I spent $47.92
Perimeter Insulation4sheets of 4x8' foam building insulation, 1" thick, interior (white) $6.49 each or $25.96
Attach foamseveral tubes foam adhesive (like PL300).$3.99 each or $11.97
Screwsseveral boxes#10 by 1.5" woodscrews. $2.24 each per 25 or $6.72
Waterproof barrier1a reinforced plastic tarp, around 16 by 20 feet or larger$14.98
Interior structure and water holder1 100-foot roll of 1.25" or 1.5" (black) polyethylene water line (BLUE label is for potable water) 1.25" is $32.48
Fittings for that pipemiscadaptors, clamps, tees.
Axle mounts21" pipe flanges$3.18 each
Air pathmisc4" PVC elbows and pipe.
Axles21" iron pipe sections at least 6" long..
Water pipe connections2 .
Air path2standard flexible dryer vent hoses..
Water connections2standard washing machine supply hoses..
miscmiscmiscellaneous pipe adaptors and hardware..

This should total around $200 of materials.


Note: These instructions are for a unit that is made of very commonly available materials, which are of rather low cost. We have also designed this to be buildable by anyone who has moderate skills as a handyman. There are ways to build many variants of this unit. One example is to line the entire inside with fiberglass instead of the tarp we suggest here. Since most modern tarpaulins are actually made of petroleum-based materials, it might be that over a period of years, the bacteria might slowly decompose the tarp. Since a layer of fiberglass is actually primarily made of silicon / glass materials, that should last for many, many years, but the cost and effort would be much higher initially.

If weight is not considered an issue, it would even be possible to build this out of Corten steel, which is resistant to nearly all types of degradation.

I give permission for any person or company to build as many as 20 of these units without further permission. Beyond that number, I do NOT give authorization without a written (paper) authorization. Specifically, I do NOT give permission to any company to mass produce my invention, made out of any material, such as out of a material such as PVC, without my approval.


Construction

On a sheet of the thick plywood, make a mark 30.25" from one end and 17.75" from a long side (or 30.25" from the opposite long side). This will become the location of the axle centerline, so you can now drill a small hole there. Using that location and a 30.25" long stick or string, draw a circle around that point. The circle should just touch the opposite edge of the plywood as well as the end of the sheet. Using a sabre saw, carefully cut out that piece.
It represents most of one side of the structure, and should be 60.5" in total diameter with a D-shaped piece missing.

Place this piece on top of the remaining piece of the plywood sheet, and trace out the edge, where the curve passes through a point that is 12.5" from the (opposite) end of the sheet. When this D-shaped piece is cut out, it is the remaining part of the full circle. These dimensions were chosen such that the full circle of the full side can be made from a single sheet of plywood.

Do the same for the other sheet to get the opposite side of the structure.


Provisions for the axle now need to be installed. I have been installing "1-inch pipe flanges" at the center of both side circles, and using bolts and nuts to secure them rather than the usual woodscrews. Put the CARRIAGE BOLT heads INSIDE the chamber so that there are no sharp projections to rub against the plastic tarp. Countersunk FLAT-HEAD machine bolts could also be used here. The later pipe nipples of 1" pipe are strong enough to be the axle shaft and do not bend with the weight of all the material in the chamber.
Next, the sheets of side foam insulation can be marked out and cut very much like the plywood sheets were, except that now the desired radius is 34.25" instead of 30.25". Foam adhesive works great in mounting them. The foam is added as two separate 2" layers, or four separate 1" layers, to have an insulation rating of R-20. These side insulation slabs extend 4" beyond the circular body, so that sheets of the 1" layers of (white) foam for the circumference can be cut down the middle to get strips of 24" by 96". THAT foam MUST be the 1" thick size, and the interior type, so it can be bent enough to follow the curvature of the perimeter. If you work in a warm area, the white circumference foam should be able to bend to follow the curvature. (Exterior foam is higher density and therefore more rigid and brittle, and would break). Again, four layers of the foam around the edges provides the desired R-20 insulation.

At this point, only the foam for the one side can be mounted, with the rest of the insulation being attached later. But even it can be left for later to avoid it being damaged during construction. All the foam can be added once the device is supported on its pedestal stand, where it can be rotated to ease addition of the foam pieces.

None of this foam is ever likely to be exposed to moisture, so white is fine, where the outdoor or underground type is required for wet locations. You could always get another poly tarp and surround the whole device, for example if it could ever be rained on.

Cut the thin plywood sheet (crossways, so that it can be bent easiest) into four pieces which are now each 24" by 48". They will be the "rim" which surrounds the two side circles to form the main body of the device.

The thin plywood can be bent enough to follow that gentle curvature of the circle edges. The strips of the thin plywood are therefore screwed to the outer edge of the plywood circle, with two of the four pieces straddling the joint with the D-shaped piece for greatest strength and durability. For reasons that will be clear shortly, it is actually easiest if you ONLY screw the thin plywood pieces to ONE of the two circles at this time. This results in the thin plywood trying to flare out. A simple way to deal with this is with a 20-foot long piece of rope, which is temporarily tied around the loose edges of those thin plywood pieces to resemble the circle that they will eventually be. A tow-rope or a load-binder could also be used.

You might notice the (white) indication of the construction adhesive used to join the sidewalls to the circular pieces. Also note that the joints between those four pieces are carefully arranged to not be at the same location where the joints between the two parts of the circle are, for greater structural strength.

You now have a 60.5" diameter disk with a two-foot-high circular barrier around it.

Place the tarp inside that pit, relatively centered. It actually is slightly off center, such that all the edges of it can reach the opening you will later make in the second circular unit to feed material into the device. That makes sure that the tarp has no edges or seams or overlaps inside the chamber which might someday become less than water-tight.
Get the coil of poly pipe. We show the pipe as it is bought, along with some of the hose clamps which will be used with it.
What you are going to do is follow the natural curved shape of that poly pipe (because it is bought in a coil). You are going to use two standard hose clamps, but not in the traditional way. You will use a short piece of metal barstock, between two turns of coil of the pipe, to clamp each of the two clamps to which makes a poly pipe circle of a very specific and very sturdy diameter. You will slightly increase the diameter of the first loop, up to where the OUTSIDE diameter is slightly over 60.5". The two clamps are on the two turns of the coil, with the end one about a foot or two from the very end of the poly pipe, but the two clamps are linked together to establish this sturdy diameter. When they are tightened, they will fix that outside diameter of that ring of poly pipe to slightly greater than the diameter dimension you choose. That diameter is chosen so that the coil will be a very tight fit, virtually a press-fit, inside the chamber. When it is pressed down into the corner of the chamber, it will securely hold the tarp in the corner there. Roughly one foot of the pipe extends beyond where the clamp is, so that a water connection can be made.

It is very important to make sure that no sharp corners of any metal could ever rub against and tear the tarp. Wrapping a layer of non-biodegradable duct-like tape is a reasonable way of protecting the tarp surface from all the clamps.

There are also around eight to a dozen extra clamps needed on that first turn of pipe. (the photo shows only the first loop in place, with the rest of the poly pipe still waiting to be spread out to press against the circular walls.) The extra hose clamps will be roughly equally spaced around the circumference of the ring, to be able to clamp upward metal spacer bars securely to the pipe and later also to the identical poly coil which will be made for the opposite corner of the chamber. The spacer bars can be either 1/8 by 3/8 flatbar strips or 5/16 or 3/8 diameter round rod. For the standard size of chamber described here, 24 inch long pieces of that rod or bar are fine. Around 2.5 inches from each end, a right angle bend is made, with the result being a sturdy spacer bar which will keep the two outermost coils of poly pipe at 19.25 inches apart. (The curved plywood perimeter is 24 inches, minus two pieces of side plywood and the two diameters of poly pipe, leaving very close to 19.25 inch separation needed).

Notice that the detail of the narrow photo here shows that I put a twist in the flatbar stock, which allows the barstock to fit more closely along the sidewalls, which allows the poly pipe to fit better.

The radius of the first and last loop keeps the pipe pressed against the outer (circular) wall and the spacer bars keep the pipe circles pressed firmly against the sidewalls. The rest of the pipe, around five turns, is reasonably snugly pressed against the outer wall. A few additional standard stainless steel hose clamps are used to clamp the intermediate loops to a FEW of the spacer bars, to keep them spaced apart across the width of the chamber, roughly with 3" spacing between each loop.

I am also experimenting with other methods of affixing the poly pipe to the spacer bars. The cheapest and simplest is to use electrical Cable Ties, (shown as the attachment type in the next photo here, to attach to the middle spacer bar shown, but nearly invisible because they are black) but I have doubts whether they will be able to stay tight over the years due to the heat and the motion. I suspect that when I check them in a few years, they may be loose! I am also experimenting with using 16 inch long pieces of scrap SOLID house wiring, wrapped DOUBLE around the pipe and spacer bar (shown in the rightmost portion of the next photo, again with black insulation on the wires so they are hard to see).. They figure to be durable, but again the motion over several years may loosen them. But they are much less expensive than the hose clamps which are clearly the best. So I am just using the standard stainless hose clamps on just the two opposite spacer bars, one being shown near the left side in that next photo) which should ensure that the poly pipe will never be able to go very far anywhere. The Cable Ties and pieces of wire are therefore not critical in the operation, and I consider them somewhat optional. If it turns out that Cable Ties will still be fairly tight after several years, that may be the future way to go.

This photo has all the turns of poly pipe securely attached. Notice that the actual spacing of the poly pipe is not critical, and I have some variation in the demo setup.

One of the main functions of this poly pipe is therefore to press the tarp against the circular corner, without needing any kind of adhesive. A second function CAN BE to contain water which will get heated. If 1.25" poly is used, the full hundred feet of it will hold and heat up around 8 gallons of water at a time. If 1.5" poly is used, 14 gallons. If 2" poly is used, around 24 gallons. If 3" poly can be found at a tolerable price, it would hold around 50 gallons of water at a time. Four-inch poly exists, but it is sold in straight sections rather than in a coil, which makes its use a little more difficult, although that would contain even more water at a time. For really big water capacities, rigid PVC 4 inch pipe is probably best and easiest. We find the 8 or 14 gallon to be sufficient, since new water coming in gets heated quite quickly due to all the tube surface area exposed to the 150ºF environment inside the chamber. Even 8 gallons of 150ºF water mixes with about 14 gallons of 55ºF tap water to easily fill a bathtub with 22 gallons of wonderful 90ºF bath water! Showers use less hot water and are even more reliable. Washing many consecutive loads of clothes in the hottest of water might be a reason to consider the larger diameter poly, or multiple coils of it inside the structure.

Below, we will calculate that if all the hot water is removed, it generally only takes about 15 minutes for new cold water to become heated fully to the 150ºF, so those hot baths could be repeated all day long, as long as they were at about 15 minute intervals!

The two outer rings of pipe therefore press the tarp into the corners of the chamber, without any adhesive and without any fasteners which might have to penetrate the tarp.

At the very ends of the coil of pipe, standard barbed elbows are attached. (the gray barbed fitting is seen near the very middle of this inner photo, elbowed up which will be extended against the sidewall). One end will be connected to an input water supply (of cold water) and the other will be connected to an output pipe of hot water. This arrangement ensures that ONLY hot water could possibly be provided, that any new cold water has to pass through the entire 100-foot length of the coil of pipe, and be fully heated up, before it could ever get to the output connector.

There are alternate ways of installing and spacing this poly pipe. Keep in mind that its primary function is to press the tarp tightly into the corners of the chamber. Having water inside it is simply a bonus regarding making hot water! By using an entire 100-foot long roll of the poly pipe, there are minimal pipe fittings that could ever later leak. It turns out that the tumbling action of hundreds of pounds of the organic material tends to knock loose any poorly attached spacers or clamps!

The second plywood circle can now be installed, again using construction adhesive and screws. Obviously, all the tarp edges are first pushed into the chamber, as shown in the first photo here. Realize that the tarp has covered up the TOPMOST circle of poly pipe, which will therefore press the tarp nicely into the circular corner there. The tarp edges will later be pulled snug along the inside surface (not visible) so that all the edges of the tarp will extend through the material feeder opening, which is indicated by the lines marked out in the second photo here. This particular unit was made to have a 16" square feed door.

I generally climbed on top of this second plywood piece, to squeeze the poly pipes and spacers inside so that everything was snug inside the chamber, and so that the top edge of this plywood piece matches up with the upper edges of the curved perimeter plywood pieces. This makes sure that nothing can move around inside the chamber. Good quality construction adhesive and screws are again used to construct this.

You can also see in the second photo here where the remaining D-shaped piece of plywood will go. Please ignore the two PVC closet (toilet) floor flanges in the photo because a better way has been found to install the air tubes.

You obviously realize that the tarp edges will be pulled through the opening and secured on the OUTSIDE of the side plywood. This will ensure that there are NO openings anywhere in the tarp surface inside the chamber, where water or water vapor could ever escape and cause unplanned decomposition of the structure itself! As long as you did not puncture the tarp anywhere, it should now essentially be able to hold water, except where the feed door assembly will be attached.


This photo shows the device with the remaining D-shaped piece of plywood added and then a trapezoidal-shaped hole was cut. This hole accomplishes many functions. We made this hole 16" in height, approximately centered between the axle shaft and the perimeter (about 7" from each). We made the top 16" wide to allow the 16" square access opening, and we made the bottom 26" wide to permit space for the large PVC pipes. First, the hole allows all the edges of the poly tarp inside to stick through, so there are NO holes or punctures anywhere in the inner tarp surface, which should make it absolutely water-tight and vapor-tight. There will be a piece of discarded industrial conveyor belting cut to be mounted over this opening, which will have five different holes cut in it. (1) a large 16-inch square hole will have a removable door over it, to allow loading in the organic materials and possibly reach inside to remove anything that has not decomposed. The hole is trapezoid-shaped to allow space for (2,3) two 4" PVC schedule-40 pipes (one through each of the wider corners). Above the PVC pipes are (4,5) two smaller holes for the poly water pipes which are inside. This hole and the covering piece of conveyor belting is large enough that if it should ever become necessary to do any work inside the chamber, it should be possible to have suitable access in there.

The second photo simply shows all the edges of the poly tarp being brought out through that hole, to show how they will all be extended a little way along the outside and then tacked or stapled to the outside, several inches back from the edges of the hole. All those edges will actually simply get pinched between the plywood sidewall and the thick piece of conveyor belting, which will securely hold it in place.


These next two photos show the device standing up in its correct upright position, with 10" long (galvanized) pipes threaded in the pipe flanges, and those pipe sections supported on sturdy triangular support pillars. The support stand has stiffeners to make sure that it could not move or collapse when a lot of weight of organic material and water is inside. We also added 6" x 24" stiffeners of the 3/4" plywood scraps over each of the seams of the perimeter 1/4" plywood, which otherwise tends to bulge out a little there.

Even with no actual bearings at all, and just the pipe sections resting on the top of the support pillars, the device rotates extremely easily. Just the couple pounds difference due to the missing wood from the hole tends to make it want to rotate so that the hole is generally upward, which indicates that only a very small motor is needed to rotate it. When the heavy piece of conveyor belting is added and the fill door, the weight changes enough that it then wants to turn the other way. A counterweight can be added opposite the fill opening, to either balance it or to get it to want to keep the fill hole naturally upward.

These two pictures obviously do not yet show the white foam insulation layers, or the conveyor belting material piece or the pipe connections or the entry door. You can note that the two pictures show the device in positions about 60 degrees apart, which commonly takes about 15 minutes to move that far. Once the foam is added, not much else is then visible except for the hole and piece of conveyor material, pipe ends and feed door.

The stiffeners we added to the chamber mean that the first layer of the 1" white foam insulation needs to be cut shorter to fit between those stiffeners, but that then allows the other three layers to fit excellently. (seen below)

We intentionally included a conventional room door in the photos to confirm that the size of this device is between 5 and 6 feet in diameter, and a little over two feet in total thickness.


The first photo here shows the first layer of the one-inch white foam skipping the area where we added the stiffeners.

The second photo here shows the four layers of that foam in place.


The first photo here shows the entire device with the perimeter foam in place (although a small section of the outer layer is not yet in place in this photo).

The front will soon be covered by the side foam, and the piece of scrap conveyor belting will cover over the trapezoid hole, where only the final 16-inch square hole will remain and the two pairs of pipes adjacent to it.

The second photo here shows the perimeter of the unit. This shows the foam left exposed. We do not see any major reason that cannot be left, with a few related thoughts. The white foam is very susceptible to being damaged, so if the device is where it might be bothered by kids or pets, it might make sense to go to the extra trouble of covering it with thin (masonite) paneling or wall paneling or even an external tarp. The white foam also disintegrates pretty quickly if it gets wet, so if that is a possibility, then the same should be done. It can also be painted, decorated, to become an active artistic object. If it is in a location in the house, kids' school projects or awards could be attached to it, where they would forever be moving around.

The blue or pink foam is far more resistant to moisture and abrasion, BUT it tends to shatter rather than bend around the curvature, so if you try to use that material, be very careful about that.


The next two photos show the piece of surplus conveyor belting I like to use for around the door and pipes. Companies that use such industrial conveyors need to occasionally replace the belting. They do NOT like to have to pay to have it hauled away, so many such companies tend to have some piles of discarded conveyor belting lying somewhere out in a field. They seem to enjoy the chance to get rid of some of it (for free!). But I have never asked for just two feet of it! I generally have taken whatever piece of scrap belting they had easiest access to. They seem to commonly chop it apart into 50 to 100 foot long pieces, just so they could more easily haul it away. The belting that I have used has all been of a thickness of 0.400 inch, but the thickness for our purposes is irrelevant. The one shown here was from a 36 inch wide conveyor (width is also irrelevant) and the piece used here was squared out to 26 inches long (high in our case). The upper corners were trimmed to better fit against the plywood backing. You may be able to see around a dozen small holes we drilled for the mounting bolts to pass through it.

The first picture shows the surplus conveyor piece with the 16 inch square hole that will be for the access door, and the two smaller round holes for the poly water pipes and the two larger round holes for the two 4 inch PVC sewer lines.

The second photo here is because these details are not easily seen when the items are mounted on the unit. It shows that a 90 degree street elbow immediately goes through each of the larger holes, one pointed up and the other down. The reason for this may turn out not to actually be that important, but we think it might be. You will be feeding in air, consisting primarily of oxygen and nitrogen into one of these large pipes (on the far side), and "used air" containing a substantial amount of carbon dioxide will therefore be pushed out the other (nearer pipe). It turns out that carbon dioxide is more than 1.5 times as dense as normal air. We believe that there is very little air motion inside the chamber, so maybe a good deal of the carbon dioxide might settle toward the bottom (rather than the normal action of simply mixing with the air). So we provide the longer (26") PVC pipe going downward to be able to remove the gases down near the bottom, which we expect to contain an excess of carbon dioxide. This, while the air/oxygen that we are sending in might tend to initially stay nearer the top, so we provide the upward (11") pipe to cause the air sent in to stay farther from the used gases that we want to exhaust.

It will require thorough chemical analysis to determine this, but for now we are assuming it to happen. In the event that the carbon dioxide and air mix more than we are expecting, the only real difference is that a larger blower is needed to expel more of the air inside the chamber to replace it with fresh air for the bacteria to use.

IF the "exhaust" gases are to be used to (later) provide increased carbon dioxide for a high-performance greenhouse, we think this simple feature might allow a greater percentage of carbon dioxide in that exhausted air, while also then requiring less power in the air blower to cause that circulation.

Once this assembly is in place, none of it is easily visible, so it is shown here separate from the device.

Finally, not yet shown here are the standard "closet (toilet) flanges" to mount those pipes really securely without having to make any holes in the tarp lining inside the chamber. But since the street elbows have some radius, we found it necessary to mount the closet flanges slightly raised up, on 2x10 lumber scraps, to get the PVC pipes inside the chamber nearer to the side wall, to less interfere with the movement of all the material that you will put inside it to tumble around. These flanges and the mounting will be more obvious in the next photos.


The plumbing (and potentially air) connections would be an additional problem if the device was allowed to always rotate in one direction. There ARE special rotary fittings available but they tend to be expensive. Instead, we have designed it where the entire assembly rocks back and forth, ONLY ROTATING ABOUT 3/4 turn and then reversing. All of the material inside still gets to be gravity-tumbled inside, but the plumbing and air path connections become far simpler. The air hoses for air/oxygen in and carbon dioxide out can then be simple standard clothes dryer vent flexible hoses. The water connections can be standard hoses used to connect a washing machine to house piping. They should all last a number of years. Keep in mind that this rotates so slowly that it is hard to even notice, the FASTEST being around once per hour. (A tiny (hobby) electric motor which might be used to rotate the drum might then be DIRECT CURRENT, where simply using a relay to reverse the wires makes the motor turn the other way, so it could oscillate back and forth its 270º of rotation. This limited rotation aspect also permits adding a "cooking chamber" which would never have to cross under the mass of material inside the chamber.

You have scraps of pieces of the thicker plywood. An optional feature you might consider is to cut out a number of arc shaped pieces, which have an inner radius of maybe 28" and an outer radius of slightly over 34.5". They would be mounted to either of the side wood circles (by screws and construction adhesive) such that a larger radius of the plywood (of just over 34.5") is present there. The only purpose for this is so the wood could extend beyond the 4" thick of foam insulation which will surround the entire structure. A tiny motor could then rub against that (circular) edge to very slowly rotate it. The rotation rate only needs to be once per hour, so a very tiny motor would be fine for that. (It CAN be rotated faster if you wish but there is no known advantage in doing so.)

A "trap door" then must be made in one of the sides. It should not be closer than 6" from the circular rim, but can otherwise be of somewhat optional shape and size. It will provide a way for you to reach inside to mount the few last small items, and it will also be the opening through which you will later add organic materials. It obviously should be large enough so both of these tasks are as easy as possible.

The door needs to fit decently tightly, and it needs to have a SEPARABLE provision for its two or four layers of foam insulation attached to it. The outdoor foam can be an advantage for the outermost layer, just to be more abrasion resistant.

The "remaining items" are the water pipe connections and the airflow connections.

We know that we desire a standard decomposition rate of around 5 pounds of material per hour, with a maximum of 10 pounds per hour. From our previous discussions in related web-pages regarding the biochemistry of what is going on, we know that this will create around 45,000 Btu/hr (90,000 Btu/hr) of heat. We also can calculate the amount of air needed and exhaust removed for those decomposition rates. You can confirm this with the equations given in those other pages. We learned that about 12.6 gram-moles of chemical reaction occurs per hour. The five pounds of glucose combines with about 5.3 pounds of oxygen in the intake air, to form about 7.3 pounds of carbon dioxide and about 3 pounds of water (or water vapor). Air is only around 1/5 oxygen, so we will need around 26 pounds of air per hour, each of which takes up around 13 cubic feet. This means that we need an INFLOW of around 338 cubic feet per hour, or 6 cubic feet per minute (6 CFM). Because of the Law of Partial Pressures, the outgoing exhaust air cannot be more than around 4.4% carbon dioxide. We know that we need to exhaust about 7.3 pounds of carbon dioxide every hour, so this means that we need to exhaust around 140 pounds of exhaust AIR each hour, which each take up around 14 cubic feet (due to the higher temperature of that exhaust gas). This tells us that we should expect to need to exhaust around 1960 cubic feet per hour of air or 33 CFM.

We should use this larger number regarding the exhaust in designing the airflow through the system. When we reduce the actual airflow, the main effect is that there is still a lot of carbon dioxide near the bacteria, so they can less easily get to oxygen, which can slow down the process. In other words, we can have a moderate level of control as to how efficiently the bacteria are decomposing the material in the chamber by how regularly we have the small blower pushing new air/oxygen into the chamber. We may also want to double that capability, in case we should ever want it to decompose the maximum 10 pounds per hour, which means we should provide airpath sizes where 66 CFM of air can pass. We choose to use a 4" dryer duct size of connection for the airflows, along with a very small blower (in the INLET side) which can move around that level of airflow. This is actually a convenient size, as it means that commonly available flexible dryer vent hose can be used.

The (two) 4" diameter holes are made with their centerlines 4" in from the outer edge (in other words, 27" from the axle. We chose to use (toilet) closet floor flanges, to be able to ensure that we can mount them with no moisture or air leaks due to the fact that we have to penetrate the tarp there. Caulking is used UNDER the flange (and against the tarp) for this reason. Flat-headed bolts are used to mount these closet flanges rather than the usual wood screws, for better strength and durability.

One is mounted near one side of the circle, and the other is mounted on the opposite side of the (same side) circle. One will generally stay near the top (due to the oscillatory motion) and it will provide air/oxygen IN for the device, but ONLY when it is near the top as it rotates. The other will then be near the bottom, where the more dense (heavier) carbon dioxide tends to accumulate. Due to the air/oxygen being pushed into the chamber by the blower, the carbon dioxide will be forced out through that lower hole. Standard 4" PVC elbows and pipe sections (just beyond the 4" thickness of the insulation) gets this connection to be near the axle shaft where the flexible dryer vent hose attaches to it there, to finally connect to 4" PVC pipes which are mounted to the fixed support stand of the system.

If the capability of providing domestic hot water is to be also used, those connections can be handled in similar ways, where the connection uses standard (flexible) clothes washing machine supply hoses for the water connections, also near the axle of the system so that there is minimal actual motion of the flexible hoses. Such hoses usually come with a built-in filter which should be removed for greater water flow rates.


Standard (micro) switches could be installed to stop the device from rotating beyond the desired 270º of rotation and to cause the motor to reverse, so it would then constantly oscillate back and forth. This actually results in one portion of the inside of the chamber never having to pass through the puddle of water that is always kept in the bottom. An attractive possibility which I am currently (12/07) experimenting with is where a (sturdy) 6" or 8" diameter thick aluminum pipe is installed across the entire 24" width of the chamber, but which has an end cap and is well grouted to be watertight. I see this as an attractive "cooking chamber" where even hard boiled eggs (without any water!) and hamburgers can be cooked. The cooking is at a slower rate than on a stovetop burner, but the 150ºF temperature of the chamber is quickly conducted through the aluminum walls to provide close to a 150ºF cooking temperature. That is plenty to kill any dangerous germs (only around 125ºF is needed for that), and food seems to cook very evenly, without ever burning the surfaces, in around two to three times as long as on a stovetop! I am looking forward to seeing if spaghetti can be cooked in it!

This (smaller) unit has a total diameter of around 5'9" so it can easily be carried (or rolled) through normal doorways. However, the width dimension of what we have described here is essentially 32", so if it has to pass through a standard 32" wide interior doorway, you may need either hold off installing one layer of the side foam or remove the casing trim of the doorway!

This unit has a total surface area of about 72.5 square feet. The insulation that we have described is all R-20. The temperature difference if this unit is placed in the heated portion of a house is around (145ºF - 70ºF) 75ºF. This indicates that the heat loss outward through the insulation is 72.5 * 75 / 20 or 272 Btu/hr. This very minimal loss allows the contents of the chamber to rapidly get up to its operating temperature. (This very low value might indicate that future units might not need quite as much insulation, to still perform well.)

When the chamber contains 400 pounds of organic material and also 200 pounds of water, the thermal capacity is around 350 Btu/degree. That means that it first requires 350 times 75ºF or 26,000 Btus of heat to be internally developed to first get up to 150ºF. It also means that the interior material can release 350 * 25ºF or around 9,000 Btus of energy in dropping the interior temperature the 25ºF from 150ºF down to 125ºF, the general range of operation of the thermophilic bacteria of this device. If the entire amount of 150ºF hot water is removed (as for clothes washing or a really hot bath), when the pipe all fills with cold (55ºF) water, it briefly uses much of the capability of the system to heat up all that new water up to the 150ºF, a process that generally should only take around 15 minutes of the heat to accomplish. The warm air heating capability therefore drops somewhat when large amounts of hot water are withdrawn, but recovery is generally within 15 minutes max.

Getting Heat Out For the House

There are multiple ways to get the usable heat out of this device for a house. They each have different overall efficiencies, complexities, costs, and potential advantages and disadvantages. These different methods use the exact same device described in the construction above. These are presented in no particular order:


There seem to be endless new uses for this critter! Here are several more that I have started to experiment on!


I find the need to add a personal comment here! An immense number of people seem to not comprehend the concept of a GIFT! The exact same thing occurs in the Free Air Conditioning web-pages, which I have provided, FOR FREE, since late 2000, where all the necessary construction and planning information is included, as well as all the information regarding the Engineering concepts behind why it works so well. However, so far, over SIX THOUSAND PEOPLE have DEMANDED that I provide them PROOF that it works! Several thousand others have demanded that I give them names and addresses and phone numbers of some of the 9,000+ people who have installed and are using the (Free A/C) system. The same is already starting regarding this HeatGreen heating system.

This information is provided by a fairly intelligent Nuclear Physicist FOR FREE! I thought that was a nice and generous gesture! WHY do people think they deserve to get "free custom personal Engineering" or to receive whatever they might consider to be proof or to be allowed to annoy some happy family with hours of endless questions? This DID used to sometimes happen with the JUCA Super-Fireplace whole-house-heating woodstove that I DID actually sell for many years. The owners nearly always found it very annoying, except for people who THEY INVITED to their homes! But when a CUSTOMER was considering BUYING A PRODUCT, it seemed vaguely credible that they might want to annoy owners of my woodstoves like that. A woman from Alaska ended that! She DEMANDED that I give her a dozen names and phones of owners (who had each generously offered to talk to potential customers). I expected her to pick out one of the twelve, and then to make a politely brief phone call. But NOOOO! She spend a dozen evenings, calling each of those families for phone calls which I was told were all between two to three hours! The entire quiet evening for a family was gone for every single one of those wonderful families! (All that to consider buying a $1400 woodstove which we had GUARANTEED [since 1989] to be able to ENTIRELY HEAT ANY HOUSE.) But she alone managed to infuriate all dozen of those people, each of whom then immediately asked to have their names removed.

A single inconsiderate woman really destroyed a fine way that JUCA owners had been previously able to help people who are not familiar with the performance of JUCA units. Unbelievable. Now, do YOU think that I am going to put ANYONE at risk of having that happen to them, WHEN THERE IS NOT EVEN ANY PRODUCT BEING SOLD?

(I may have a very old Bridge in Manhattan to sell you if you do!) But separate from that, apparently no one has ever heard of the Gift Horse story! For the Free Air Conditioning, and for this HeatGreen system with its several configurations, and with the free system to monitor Children's Bodyfat in a fun and easy way, and in the method to try to drag Beached Whales back to the ocean, and on and on; IF you demand PROOF, then I would PREFER that you simply go away and stop bothering me. Go stare in the mouth of some horse somebody has offered to give to you! In fact, I make VERY sure that I provide massive Engineering and scientific proofs for each of the statements made regarding any of these systems which I offer.

You actually DO have access to a way to PROVE that the HG3a or the Free A/C works as described. You could HIRE a top quality Thermodynamics Engineer (at around $400/hour), and he/she can then duplicate the Engineering which I provide in the web-pages. A talented Engineer should be able to research that my information is sound and then calculate the needed things in maybe 25 to 40 hours of work. Of course, this means that you will have to pay that Engineer between $10,000 and $16,000 to confirm the information WHICH I HAVE GIVEN YOU FOR FREE!

In order that you not waste $200 on building materials from a local store!

I can only say, DUH!

Please do NOT be annoying me with demands for proof (before you dare spend $200 for materials), OR where you will insist that YOUR application IS UNIQUE and you therefore REQUIRE me to personally Engineer (the exact same unit) for your needs. IF you are willing to pay me at the standard $400/hour rate for such advanced Engineering, and will provide a Retainer for a number of hours to start with, I MIGHT be willing to listen. But probably still NO! If you are so convinced that you have a totally unique situation, then get that local Engineer to do the Engineering and Design for you!


The main presentation was first placed on the Internet in February 2007. This high-performance version presentation was first placed on the Internet in November 2007.



Links to energy-related pages in this Domain:
Global Warming Calculated by a Physicist
Global Warming and Climate Change - Possible Physics Solutions
Unlimited Hot Water FOR FREE, while Solving Global Warming!
Heat Your Whole House FOR FREE, while Solving Global Warming!
Current Energy Resources in Existence (Scary!)
Making all (Black) Asphalt Roads, Rooftops and Parking Lots White can help with Global Warming!
Global Warming Issues Regarding HEAT Sent into the Atmosphere
Global warming Issues Regarding Carbon Dioxide, and Sealevels Rising
Hydrogen as an Fuel-source Replacement
A 100%-Solar Home Heating System
Solar Electricity from PV Photovoltaic Cells
Batteries or Hybrids as an Fuel-source Replacement
Wind-Power for Making Electricity

The Earth's Rotation as a Source for Energy
Waste Nuclear Power For Making Electricity And Heat?
The Physics of Efficiency In Electric Power Plants
Individual Ways of Reducing Your Energy Usage
Methods of Storing Energy for Later
How Much Energy Comes From the Sun? And Why is there Global Warming?
How does the Sun create so much energy?
Inventions Which Might Help Deal With Coming Energy Catastrophes
An Invention to Efficiently Make Electricity from Solar
Enormous Heating of the Atmosphere by the Alaska Pipeline
Air Conditioning without Huge Electric Bills and without Freon
A Method of Storing Summer Heat to (Nearly) Entirely Heat a House all Winter
An Extremely Highly-Efficient (and Fast, 200.0 mph) Transportation System for People and Products
The Sophisticated Woodstove I Invented in 1973

The Physics of Wood as a Heating Fuel
Why is the North Pole Heating Faster than the rest of the Earth?
A Possible way to greatly reduce Aerodynamic Drag of Airplanes




Link to the Index of these Public Service Pages

( http://mb-soft.com/public/index.html )



E-mail to: Public1@mb-soft.com

C Johnson, Physicist, Physics Degree from Univ of Chicago