Development of a high-efficiency, gas-fired, heat pipe, warm-air heating system

With the introduction by Borg-Warner of the Heatpipe Furnace, one of the major goals of this program was achieved. This milestone was reached after a 105,000 Btu/hr, 85 percent efficient manufacturing prototype heat pipe furnace was designed, fabricated, and tested by Thermo Electron. Other prototype units of different capacities were also designed. The prototypes underwent extensive field testing and in-house accelerated life-cycle testing, indicating that they were reliable, safe, and cost-competitive. Specific issues like freeze protection and oil contamination were addressed. Two different prototype ultrahigh-efficiency condensing furnaces were designed, fabricated and tested. One approach utilized a fluorocarbon-filled heat pipe as a secondary-stage heat exchanger; the other used a plate finned tube coil as the heat exchanger.