10/25/2018

Broiler house heating system design Why is controlling the environment

requirements important?
 In order to maximize bird performance and health you
must be able to control the environment within a poultry
house.
100

 air temperature 90

80

70

 air quality 60

Temperture
Set temperature
50 s2
outside temp

air movement
40

 30

20

light
10

 0
12/30 1/4 1/9 1/14 1/19 1/24 1/29 2/3
Date

Why is controlling the environment To control air temperature, air quality, air movement
important? and light you need a properly designed:
 The more control you have over these variables, the  Heating system
more control you will have over bird performance  Ventilation system
100

90
 Lighting System
80

70

60
Temperture

Set temperature
50 s2
outside temp
40

30

20

10

0
12/30 1/4 1/9 1/14 1/19 1/24 1/29 2/3
Date

A heating system must be able to meet

certain objectives: Specifically
1) Provide a minimum air temperature of 90oF…
 on the coldest day of the year …
 with day-old-chicks
 while at the same time providing good air quality.

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Heating system objectives: Heating system objectives:

2) Minimum floor temperature of 90oF 3) Energy efficient
 Ideally with areas of the house having significantly warmer floor
temps (+110oF)

Our ventilation system also has to meet

Heating system objectives: certain objectives…
4) Relatively easy to manage and maintain

Specifically… Ventilation system objectives:

1) To provide sufficient fresh air to the house to maintain 2) To provide sufficient fresh air to control house
proper air quality without causing excessive bird temperature
chilling.  cold to moderate weather
 hot weather

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With these objectives in mind, we can now start to

design a heating/ventilation system for a broiler
Ventilation system objectives: house
1) To provide sufficient fresh air to the house to maintain  When it comes to a heating system…what is the best
proper air quality without causing excessive bird way to determine what we need?
chilling.
2) To provide sufficient fresh air to control house
temperature
3) To accomplish objectives #1 and #2 with a minimum of
energy use.

How do we determine how much heat or

how many heaters we need? The best way is to conduct a “Heat Balance”
 Basically calculate how much heat will be lost from the
poultry house each hour…then put enough heaters to
make up what is lost.

The fact is heating the air in a poultry house For instance, let’s say we have a 40’ x 500’ broiler
is relative easy house with average ceiling height of 9.5’

 Volume to fill with hot air

 Width x length x average ceiling height
 40’ x 500’ x 9.5’ = 190,000 cubic feet of air

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Calculating time to heat the air in the Calculating time to heat the air in the
house… house…

 We can calculate the time required to fill the house with

500oF air by simply taking the volume of the house and
dividing by 1,200
 190,000 cubic feet / 1,200 cfm = 158 minutes
 A single furnace produces 1,200 ft3 /min of air with a
 = 2.6 hours
temperature of 500oF.

The problem is keeping it full! Poultry house heat loss

 Heat flows from warm to cold

As we are adding heat….it is continually “leaking” out

Thermal image of broiler house show heat

loss from a poultry house
70.0°F
70

65

60

55

52.0°F

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Curtain-sided house
(outside temp = 50oF, inside 85oF) Curtain-sided vs. Solid sided
70.0°F
75.0°F 70

75
65

70 60

55
65
52.0°F
70.0°F
70

60
65

55 60

55

50.0°F 52.0°F

To determine how much heat a house

needs… Heat loss rate through house surfaces
 We have to determine how much heat is leaving the  How quickly heat leaves through a surface depends on:
house through …  The size (length X height) of the surface
 House surfaces:
 ceiling
 side walls
 end walls
 curtains 55.0°F
55

 Ventilation 50

 Leakage 45

40

35

30
30.0°F

Heat loss rate through house surfaces Heat loss rate through house surfaces
 How quickly heat leaves through a surface depends on:  How quickly heat leaves through a surface depends on:
 The size (length X height) of the surface  The size (length X height) of the surface
 Temperature difference across the surface  Temperature difference across the surface
 Insulation value of the surface components (R-value)

55.0°F 55.0°F
55 55

50 50

45 45

40 40

35 35

30 30
30.0°F 30.0°F

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Different R-values…Different heat flow rates

(outside temp=25oF, inside temp=85oF)
65.0°F

60

High insulation level…

Low rate of heat loss
50
Low insulation level…
High rate of heat loss
40

30

25.0°F

Calculating wall and ceiling heat loss rates House heat loss example:
 Heat loss = (Area / R-Value) x Temperature differential  40’ x 500’ broiler house
 The larger the wall area the greater the heat loss rate.  8’ side wall (2 x 6’s)
 The higher the R-Value the slower heat will leave the house.  4’ curtain
 The greater the temperature difference across the wall or
 dropped ceiling (3 1/2” of
ceiling, the faster heat will leave the house.
blown cellulose)

First, we are going to calculate heat loss

rate through each of the building surfaces: Ceiling heat loss rate
 Ceiling  Heat = (Area / R-Value) x Temp. diff.
 Side walls
 End walls  Area =W x L
 Curtains  = 40.5’ x 500’
 = 20,250 ft2
 R-Value =?

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Determining insulation values Materials ……

 Reference books  that “trap” air have high thermal R values (like the
 ASHRAE Handbook of Fundamentals feathers of a down jacket)
(American Society of Heating, Refrigerating & Air-Conditioning  that are good electrical conductors have poor R-values
Engineers) (metals, water, etc.)
 Midwest Plan Service
 that are dense (masonry, stone, steel, etc.) have poor R-
 Etc.
values.
 Insulation manufacturers
 caution
 Internet (caution)

Building R-values
(the higher the value…the better the insulator) Ceiling heat loss rate
Building material R-value Building material R-value  Heat = (Area / R-Value) x Temp. diff.
(per inch) (per inch)
Fiberglass batt 3.14 Soft wood lumber 1.25
Fiberglass blown 2.2 Plywood 1.25
 Area =W x L
Cellulose blown 3.13 Cedar 1.33  = 40.5’ x 500’
Rock wool blown 3.14 Poured concrete 0.8  = 20,250 ft2
Air-entrained concrete 3.9  R-Value =?
Rigid fiberglass 4.0 Building material R-value
Urea terpolymer foam 4.48 Aluminum/steel siding 0.6
Expanded Polystyrene (beadboard) 4 Concrete block 4” 0.8
Extruded Polystyrene 5 Concrete block 8” 1.11
Polyurethane (foamed in placed) 6.25 Concrete block 12” 1.28
Polyisocyanurate (foil-faced 7.20 Brick block 4” 0.44

3.5” X 3.13 = 11
Building R-values Air films R-values
Building material R-value Building material R-value
(per inch) (per inch)
Fiberglass batt 3.14 Soft wood lumber 1.25
Fiberglass blown 2.2 Plywood 1.25
Cellulose blown 3.13 Cedar 1.33
Rock wool blown 3.14 Poured concrete 0.8
Air-entrained concrete 3.9
Rigid fiberglass 4.0 Building material R-value
Urea terpolymer foam 4.48 Aluminum/steel siding 0.6
Expanded Polystyrene (beadboard) 4 Concrete block 4” 0.8
Extruded Polystyrene 5 Concrete block 8” 1.11
Polyurethane (foamed in placed) 6.25 Concrete block 12” 1.28
Polyisocyanurate (foil-faced 7.20 Brick block 4” 0.44

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The insulation value of an air film is caused by the Air films add to the insulation value of walls
friction induced by a surface on moving air …. and ceilings

Air films add to the insulation value of walls

Air films R-values and ceilings

Building material R-value

Wall air film (interior) 0.7

Ceiling air film (interior) 0.6

11 + 0.6 + 0.2 = 12
Air film (exterior) 0.2

R-values Ceiling heat loss

 3 1/2” cellulose = 12  Heat = (Area / R-Value) x Temp. diff.

 Area =W x L
 = 40.5’ x 500’
 = 20,250 ft2
 R-Value = 12
 Temp Diff. = outside temp - inside temp

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Heating system objectives: Ceiling heat loss rate

 Provide a minimum air  Heat = (Area / R-Value) x Temp. diff.
temperature of 90oF…
 on the coldest day (at  Area = L xW
night) of the year …  = 40.5’ x 500’
 with day-old-chicks  = 20,250 ft2
 while at the same time  R-Value = 12
providing good air quality.
 Temp Diff. = outside temp – 90oF

Design outside temperatures Outside design temperature data

 From weather service historical data or the ASHRAE
Handbook of Fundamentals

 99% design Winter Dry-Bulb temperature

(the low temp exceeded only 1% of the hours during
December, January & February)

 Safety factor, subtract 10oF

Design outside temperatures Ceiling heat loss rate

 From weather service historical data  Heat = (Area / R-Value) x Temp. diff.
 99% design Winter Dry Bulb temperature  Area = L xW
 Safety factor, subtract 10oF  = 40.5’ x 500’
 Tuscaloosa, Alabama  = 20,250 ft2
 99% design temperature = 20oF  R-Value = 12
 Design outside temp = 20oF – 10oF  Temp Diff. = 10oF – 90oF
 = 10oF

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Ceiling heat loss rate

(3 1/2” of fiberglass) Heat loss rate through building surfaces:
 Heat = (Area / R-Value) x Temp. diff.  Ceiling = -135,000 Btu/hr
 Area = 40.5’ x 500’
 = 20,250 ft2  We have to replace this amount of heat or our house
 R-Value = 12 temperature will decrease
 Temp Diff. = 10oF – 90oF
 = -80oF
 Heat = (20,250 ft2 / 12 ) x -80oF
 = -135,000 Btu/hr

We typically burn propane/natural gas to

offset this heat loss.. Replacing ceiling heat loss
 Burning one gallon of propane produces 92,000 Btu of  To offset the 135,000 Btu/hr of heat loss through the
heat. ceiling, we need ….
 conventional brooders burn 0.33 gals/hr  4.5 conventional brooders
 produces 30,000 Btu/hr  3.4 radiant brooders
 radiant brooders burn 0.43 gals/hr  0.7 furnaces
 produces 40,000 Btu/hr
 furnaces burn 2.2 gals/hr
 produces 200,000 Btu/hr

What happens when we increase ceiling Ceiling heat loss rate

insulation? (6” of fiberglass)
 Heat = (Area / R-Value) x Temp. diff.
 Area = 40.5’ x 500’
 = 20,250 ft2
 R-Value = 21
 Temp Diff. = 10oF - 90oF
 Heat = (20,250 ft2/ 21 ) x -80oF
 = -77,142 Btu/hr
 (43% decrease)

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What if we double it again? What if we double it again?

Ceiling heat loss rate (12” of fiberglass) Ceiling heat loss rate (12” of fiberglass)
 Heat = (Area / R-Value) x Temp. diff. Insulation R value Heat Loss
 Area = 40.5’ x 500’ Thickness (BTU/hr)
3.5” 12 135,000
 = 20,250 ft2
6” 21 77,142
 R-Value = 40
12” 40 40,500
 Temp Diff. = 10oF - 90oF
 Heat = (20,250 ft2/ 21 ) x -80oF  Double the insulation (and cost)
 = -40,500 Btu/hr  Cut heat loss approx. in half

 (47% decrease)  Double the insulation (and cost) again

 Cut heat loss by half again (25% of original value)

How does heat loss change if the house has Ceiling heat loss
an open ceiling? (open ceiling)
 Open ceiling will cost more to heat
But not because of an increase in volume of air that we
need to heat

How does heat loss change if the house has How does heat loss change if the house has
an open ceiling? an open ceiling?
 Increased surface area

Lower R-value

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Open ceiling with 1” of blue board 1” X 5 = 5

insulation Building R-values
Building material R-value Building material R-value
(per inch) (per inch)
Fiberglass batt 3.14 Soft wood lumber 1.25
Fiberglass blown 2.2 Plywood 1.25
Cellulose blown 3.13 Cedar 1.33
Rock wool blown 3.14 Poured concrete 0.8
Air-entrained concrete 3.9
Rigid fiberglass 4.0 Building material R-value
Urea terpolymer foam 4.48 Aluminum/steel siding 0.6
Expanded Polystyrene (beadboard) 4 Concrete block 4” 0.8
Extruded Polystyrene 5 Concrete block 8” 1.11
Polyurethane (foamed in placed) 6.25 Concrete block 12” 1.28
Polyisocyanurate (foil-faced 7.20 Brick block 4” 0.44

Air films R-values Air space R-values

Building material R-value

Wall air film (interior) 0.7

Ceiling air film (interior) 0.6

Air film (exterior) 0.2

5 + 0.6 + 0.2 = 5.8

Ceiling heat loss rate

Air films/Air space R-values (open ceiling)
 Heat = (Area / R-Value) x Temp. diff.
Building material R-value  Area = 42’ x 500’
 = 21,000 ft2
 R-Value = 7
Wall air film (interior) 0.7  Temp Diff. = 10oF - 90oF
 Heat = (21,000 ft2 / 7 ) x (- 80oF)
Ceiling air film (interior) 0.6
 = -240,000 Btu/hr
Air film (exterior) 0.2  about double

Air space (1/2” – 4”) 1.0

5 + 0.6 + 0.2 + 1 = 7

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Calculating heat loss through building

surfaces: Side wall heat loss rate
 Ceiling  Heat = (Area / R-Value) x Temp. diff.
 Side walls
 Area = L xW
 = 4’ x 500’ x 2
 Temp Diff. = outside temp - inside temp
 = 10oF – 90oF
 R-Value = ?

R-values 2” X 6” wall R- Value

 2” x 6” wall with metal: R = 4

1.5” X 1.25 = 2
Building R-values 2” X 6” wall R- Value
Building material R-value Building material R-value
(per inch) (per inch) 2
Fiberglass batt 3.14 Soft wood lumber 1.25
Fiberglass blown 2.2 Plywood 1.25
Cellulose blown 3.13 Cedar 1.33
Rock wool blown 3.14 Poured concrete 0.8
Air-entrained concrete 3.9
Rigid fiberglass 4.0 Building material R-value
Urea terpolymer foam 4.48 Aluminum/steel siding 0.6
Expanded Polystyrene (beadboard) 4 Concrete block 4” 0.8
Extruded Polystyrene 5 Concrete block 8” 1.11
Polyurethane (foamed in placed) 6.25 Concrete block 12” 1.28
Polyisocyanurate (foil-faced 7.20 Brick block 4” 0.44

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Air films/Air space R-values 2” X 6” wall R- Value

4
Building material R-value

Wall air film (interior) 0.7

Ceiling air film (interior) 0.6

Air film (exterior) 0.2

Air space (1/2” – 4”) 1.0

2 + 0.7 + 0.2 + 1 = 4

What if we had a composite wall?

plywood, fiberglass, sheet metal? 2” X 6” wall R- Value
4
0.7+0.6+11+1+0.2

Total R-value approximately = 14

Heat loss rate through

Side wall heat loss rate building surfaces:
 Heat = (Area / R-Value) x Temp. diff.  Ceiling = -135,000 Btu/hr
 Area = 4’ x 500’ x 2  Side wall = -80,000 Btu/hr
 = 4,000 ft2
 R-Value = 4
 Temp Diff. = 10oF - 90oF
 Heat = (4,000 ft2 / 4 ) x -80oF
 = -80,000 Btu/hr

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Calculating heat loss rates through building

surfaces: R-values
 Ceiling  2” x 6” wall with metal, R=4
 Side walls
 End walls

Heat loss rate through

End wall heat loss rate building surfaces:
 Heat = (Area / R-Value) x Temp. diff.  Ceiling = -135,000 Btu/hr
 Area = 9.5’ x 40’ x 2  Side walls = -80,000 Btu/hr
 = 760 ft2  End walls = -15,200 Btu/hr
 R-Value = 4
 Temp Diff. = 10oF - 90oF
 Heat = (760 ft2 / 4 ) x -80oF
 = -15,200 Btu/hr

Calculating heat loss rates

through building surfaces: R-values
 Ceiling  Side wall curtain R= 1.5
 Side walls
 End walls
 Curtains

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Curtains R-value Curtain heat loss rate

0.3 – 0.4  Heat = (Area / R-Value) x Temp. diff.
0.7 0.2  Area = 4’ x 500’ x 2
 = 4,000 ft2
 R-Value = 1.5
 Temp Diff. = 10oF - 90oF
 Heat = (4,000 ft2 / 1.5 ) x – 80oF
 = -213,333 Btu/hr

R-value approximately = 1.5

Heat loss through building surfaces: Total heat loss through building surfaces:
 Ceiling = -135,000 Btu/hr  Ceiling = -135,000 Btu/hr
 Side wall = -80,000 Btu/hr  Side wall = -80,000 Btu/hr
 End wall = -15,200 Btu/hr  End wall = -15,200 Btu/hr
 Curtain = -213,333 Btu/hr  Curtain = -213,333 Btu/hr
 Total = -443,533 Btu/hr

Half House brooding Half House brooding

 Ceiling is cut in half
 Curtains are cut in half
 Side walls are cut in half
 End wall is cut in half
 Brooding curtain must be added

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Heat loss rates through Heat loss rates through

building surfaces: building surfaces:
 Ceiling = -135,000 Btu/hr  Ceiling = -67,500 Btu/hr
 Side wall = -80,000 Btu/hr  Side wall = -40,000 Btu/hr
 End wall = -15,200 Btu/hr  End wall = -7,600 Btu/hr
 Curtain = -213,333 Btu/hr  Curtain = -106,667 Btu/hr


Heat loss rates through

building surfaces: Brood curtain heat loss rate
 Ceiling = -67,500 Btu/hr  Heat = (Area / R-Value) x Temp. diff.
 Side wall = -40,000 Btu/hr  Area = 9.5’ x 40’
 End wall = -7,600 Btu/hr  = 380 ft2
 R-Value = 1.5
 Curtain = -106,667 Btu/hr
 Temp Diff. = 50oF - 90oF
 Brood Curtain = ?
 Heat = (380 ft2 / 1.5 ) x – 40oF
 = -10,133 Btu/hr

Heat loss rates through

building surfaces: Broiler house surface heat loss
 Ceiling = -67,500 Btu/hr end wall
 Side wall = -40,000 Btu/hr side wall
3%
17%
 End wall = -7,600 Btu/hr
 Brd. Curt. = -10,133 Btu/hr
 Curtain = -106,667 Btu/hr side wall
curtain
 Total = -231,900 Btu/hr 47%

ceiling
29%

brood
curtain
4%

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Heating requirement (brood end) Ventilation heat loss

 231,900 Btu/hr
 7.7 Conventional brooders (30,000 Btu/hr)
 5.8 Radiant brooders (40,000 Btu/hr)
 1.2 Furnaces (200,000 Btu/hr)

Ventilation and leakage Ventilation and leakage

 You have to replace heat which is exhausted through  Circa 1940’s poultry house.
ventilation and leakage.

Ventilation and leakage Ventilation and leakage

 Heat = Cfm air flow x Temperature difference X 1.07  How much fresh air entering a house depends on:
 Cfm air flow =?  timer fan settings
 Temp difference = outside temp. - inside temp.  ammonia
  moisture
 etc.
 leakage
 house tightness
 wind speed

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Ventilation and leakage Ventilation and leakage

 How much ventilation and leakage?  Heat = Cfm air flow x Temperature difference X 1.07
 20,000 cfm 30 sec on per 5 minutes is 2,000 cfm average  assume 0.3 cfm per square foot of floor space
ventilation rate. Add 1,000 cfm to cover leakage due to  Approximately 60% from timer fans, 40% leakage
must plan for the house becoming looser over time.
wind and infiltration (no fans). 

 must plan for high ammonia

 Avg. ventilation and leakage is about 3,000 cfm or
3,000cfm/10,000 sqft = .3 cfm/sqft
 Less for tight house, more for loose house
 Range might be from .25 to .35 cfm/sqft

Ventilation and leakage Ventilation and leakage

 Heat = Cfm X Temperature difference X 1.07  Heat = Cfm X Temperature difference X 1.07
 Cfm = 40’ x 250’ x 0.3 cfm/sq. ft. floor  Heat = 3,000 cfm x (10oF - 90oF) X 1.07
 = 3,000 cfm  = -256,800 Btu/hr

Heat loss rates through building surfaces

and ventilation (brood end) Broiler house heat loss
 Ceiling = -67,500 Btu/hr brood
curtain
 Side wall = -40,000 Btu/hr side wall
2%
curtain
 End wall = -7,600 Btu/hr 23%

 Brood curt = -10,133 Btu/hr

 Curtain = -106,167 Btu/hr end wall ventilation/
 Ventilation = -256,800 Btu/hr 2% leakage
51%
side wall
 Total = -488,700 Btu/hr 8%

ceiling
14%

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Calculating the number of brooders, radiant

Heating system design brooders, furnaces required (brood end)
 Once you know how much heat is lost on the coldest day  Total Heat Loss = 488,700 Btu/hr
with chicks, you know how much heat you have to add to  brooders = total heat loss / brooder output
maintain the desired house temperature and therefore  = 488,700 / 30,000
the number or brooders or furnaces can be calculated:  = 16.3 = 17
 # of brooders = heat loss / brooder output  rad. brooders = total heat loss / brooder output
 # of furnaces = heat loss / furnace output  = 488,700 / 40,000
 = 12.2 = 13
 furnaces = total heat loss / furnace output
 = 488,700 / 200,000
 = 2.4

Required number of brooders or radiant Required number of brooders or radiant

brooders brooders
 The calculated value is the rate of heat required to keep  Keep in mind that this does not necessarily mean that you
the house at the desired air temperature. have the desired amount of floor space covered with
radiant heat.
110.0°F
110

100

90

80.0°F

Furnaces Required number of furnaces

 Because of safety, spacing requirements and lack of
radiant heat...calculated furnace numbers should typically
be increased by approximately 75%
 Furnaces = Calculated x Safety Factor
 = 2.4 x 1.75
 = approximately four

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Heat loss rates through

building surfaces and ventilation: (brood
Heating system requirement approximations end)
 You can calculate the heat loss rate for all your houses to  Ceiling = -67,500 Btu/hr
determine brooder or furnace numbers:  Side wall = -40,000 Btu/hr
 takes a fair amount of time  End wall = -7,600 Btu/hr
 necessary for similar houses
 Brood Curt. = -10,133 Btu/hr
 i.e., houses of same construction but different lengths
 Curtain = -106,667 Btu/hr
 You can express heating system requirements in terms of
Btu/ft2  Ventilation = -256,800 Btu/hr
 Total = -488,700 Btu/hr

Heating system requirements for the

Heating system requirement per square foot nonbrooding end?
 Btu/ft2 = 488,700/ (40’ x 250’)
 = 48.9 Btu/ft2
 Heating system requirement for a typical dropped ceiling,
curtain-sided house is approximately ……
 50 Btu/ft2

Keep in mind this is for 40’ wide curtain-sided house

Heating system requirements for the Heating system requirements for the
nonbrooding end? nonbrooding end
 Do not need as much heat in the nonbrooding end  In the past most people installed about half the number of
because: brooders/furnaces in the nonbrooding end which were
 lower desired house temperatures at 10 to 21 days. installed on the brooding end.
 birds start producing a significant amount of heat.

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But…. Summary
 Many people are turning out at 7 – 10 days.  Heating System Design is More Complex Than We First
 Keeping warmer temperatures the first couple of weeks. Imagine
 Therefore, you should strongly consider installing at least  Location, Type of Heat, and Floor Coverage Are Three
65% of the heating capacity in rear of the house as you do Important Factors
in the brooding end.  House Tightness (Leakage) and House Insulation Are Two
Major Factors That Greatly Influence the Amount Of
Heat Needed.

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