LIVE ESTIMATE
Airflow-
State-
Melt, first of day-
VIEW
LAYERS
FIRE
AIR MODE
CRUCIBLE

Pit Forge: design viewer

Drag to orbit, wheel or pinch to zoom, right-drag or two-finger drag to pan. 1 unit = 1 inch. Design from research, nothing built or fired yet.

Click a step. The 3D scene builds up to that step and flies the camera there.

Every choice I made, why, and what I turned down. Confidence is mine, not tested.

Switch the mode with the bottom-bar buttons. The particles show the airflow path for each one.

Should the fan layout change?

Keep the four modules, change how you use them. Each module is already two rotors in series (push-pull): that doubles pressure, which is good for pushing through a bend, a pipe and a charcoal bed, but it does not add flow. Four modules in parallel give you the flow.

Depending on module size they put out roughly 1-2x the air a 10 in charcoal bore burns well at full speed. So: one manifold, a plate over unused inlets, and PWM speed control. Do not throttle by pinching the duct: it stalls the fans and wastes pressure.

The change I would make is where the air enters, not the fans: from the bottom via a plenum and buried tunnel, so the fans stay 8 ft away and the pit's depth finally does something useful.

Your fans (edit from the nameplate)

I don't know your exact part numbers. These are per module (two rotors). Read the label and fix them.

Settings

in
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Estimates

Airflow at the furnace- Back-pressure- Duct speed- Tuyere speed- Bed airflow- Charcoal burn (est.)- Fuel power- Charge in crucible- Melt time- Fan current- Power supply-

Method: fan curve is a straight line from your max flow to your max pressure, scaled for PWM (flow ~ speed, pressure ~ speed squared). System curve = duct loss + tuyere loss + Ergun pressure drop through a lump-charcoal bed. Burn rate comes from stoichiometric air for charcoal (about 8 m3 per kg) with 50% excess. Melt time uses 14% down to ~10% useful efficiency for the charge, plus the heat the dense castable wall soaks up on a cold start (the biggest single cost; a lighter insulating lining would cut it). Treat everything here as +/- 50%, and the "sweet spot" band (37 to 110 CFM per ft2 of bore) as my reasoning from stoichiometry and forge practice, not a published standard.

Read this before you dig, light or pour.