Thanks for the great reply, and sorry about mixing in non-build related questions, I just got going and apparently put down whatever questions came into my head at the time... I think I may hold off on buying a heater for now, as all my scrounging has come up blank for a side intake like yours has, and I'd like to see how yours holds up on the inside. I know that the other ones I had found start at double what your model in its currently available, top in/out form costs, so if it causes you heartburn, I can just go with the 'better' version.
The reason I had asked about water was if it went thru an RO, it should have nothing in it, and theoretically should have no deposits on anything internal, elements, tank, lines, etc. I'd think the same thing with distilled water?
The reason I asked about lbs of steam, is that for fun I was perusing Fleabay and came across this:
http://www.ebay.com/itm/371074377211?_trksid=p2055119.m1438.l2649&ssPageName=STRK:MEBIDX:IT
which it says on it's label makes 10 lbs of steam/hr. The price is very steep, but I was wondering if something that size would be able to keep up with the needs of the brewery, if one came across something similar at a screaming deal of a price? I don't know how to convert BTU's into lbs of steam.
Is a proportional valve your end goal if possible, or isn't it necessary, off and on would be good enough?
You mentioned permanently mounted coils, are there any special design considerations where cleaning is concerned?
I'll hold off on more questions, and just let you build it, watch what happens, and proceed from there. Thanks again, keep up the great work, take lots of pics, and post on the build as often as you can. All the best! Oh, and I hope next week is a lot better week for you than last week was, because I can relate, I had a _very_ bad week last week as well.
*edit* Well, while searching around about steam and HP and such, I came across this explanation of steam lb/hr via BTU calculation (below) on ask.com, and it looks like, if I did the numbers correctly, this will put out 42.2 lbs per hour if your heat input is a little over 40,000 BTU. Which makes that "big bad boiler" I mentioned above seem pretty small fry. Especially considering it is designed for that, but then, looking closer at the #'s, it is only pulling 6 amps (three phase) at 480, so that's 12a at 240 (+/- with single phase, but ballpark), so I guess it isn't such a surprise, as 12,000w is pulling 50a at 240v, that yours would stomp all over it.
"Convert the BTUs into hp units first. One unit of hp is equal to 33,472 BTUs. Thus, you will divide the BTUs by 33,472 to get your hp units.
For example, if your BTUs equal 7,363,840, then we'll divide that number by 33,472, giving us 220 hp units (7,363,840/33472 = 220).
Convert your units of hp into pounds of steam per hour by multiplying the number calculated in the previous step by 34.5.
Using numbers from our previous example, if you multiply 220 by 34.5, then you get 7,590 pounds of steam per hour created by your boiler (220 x 34.5 = 7,590)."
Just for fun I pinged the mfg of the boiler I referenced above, asking about slightly larger units, and this is what I got back:
7 lbs per hour / ampere draw 16 amps / weights approx. 65 lbs
12 lbs per hour / ampere draw 24 amps / weights approx. 150 lbs
18 lbs per hour / ampere draw 36 amps / weights approx 160 lbs
30 lbs per hour / ampere draw 48 amps / weights approx 140 lbs
50 lbs per hour / ampere draw 72 amps / weights approx 165 lbs
I did reply, asking for information on even bigger units, still single phase, he replied that he had 30, and 50, nothing in between. He also said that you will get up to 60 pph on the larger one but not warranted. Interesting info to know. And even the least expensive one is 3-4x the cost of your heating setup, and doesn't have nearly the output, which I find surprising. Guess I'm just geeking out a little bit here, sorry...