RCMJR & misoilman, tnx for your replies. RCMJR: LDJ appears to have been in business since 1999. According to the LDJ website they claim the boiler is "Great for radiant floor heat systems". I'd be interested in talking to existing users to see how they are getting on with the the system. I took a closer look at their page about the corn boiler and they claim it's thermostat controlled, perhaps it's able to be dialed down. The picture of it looks like a water heater with a hopper sitting next to it. I'll post the url for the corn boiler. The capacity of the water heater portion is eighteen gallons. They also have an option that would allow the boiler to provide hot water for "domestic" use. So would be able to heat water for shower's, washing dishes etc. Right now the utility room has two gas fired water heaters sitting in it, one for the floor heat and one for domestic use, I think. We'd have to talk the heating and plumbing guy that took over from the H&P guy that had been maintaining the system for many years. The retired fellow is still in town and we might be able to talk him into coming over and orienting us with the systems. misoilman: Having the seller comfirm the moisture content of the corn would be the first thing I would insist on when purchasing the corn. I do know from talking with the folks at the elevator, they will not accept corn that is more than 15 percent moisture. I also need to check with the city to make sure there isn't an ordinance that would preclude me from having a small gravity box sitting next to the carport. If the gravity box is small enough, I'd even consider backing it into the carport. Alas, there is no basement on this dream house. Just a thick concrete slab...:-) So We'll probably use a couple of five gallon buckets for transfer of fuel from the box to the hopper. I'd just consider it a form of exercise...:) We're also a bit concerned about the age of the plumbing in the floor as it is original to the house. The impression I got from the house inspector was that the in floor plumbing was put in place then had the concrete poured over it. I'm going to have to have someone that has better eyes than me and know's what they're looking for, look at the blueprints and see if we can find out how thick the concrete is. Luckily, we've secured a "home warranty" from the seller for at least the first year (at their expense), and there is a possibility of extending it through the second year. I should also probably state that the corn boiler is not a done deal as we are still in the early part of the research stage. Although, a friend of ours has suggested we check the website of the Governor of Illinois and see if there are any grants or other incentives that we might be elgible for. Governor Blagojevich (Bla-goy-a-vich, what a mouthful) is very interested in promoting alternative fuels and energy use in Illinois. Here is a link that might be useful: LDJ's Corn Boiler page

Our house has a similar situation. It's 1900 sf, built in the 1890's, has some blown in insulation in the walls (we only know this because we gutted the bathroom and found it - this room will have regular batt insulation in the walls and ceilings), has the original windows but triple track storms. The old oil fired boiler is 199k BTU and our oil bills are completely heinous - we used about $650 worth of oil for the month of December. I can't imagine what our bills would have been for a house 50% larger. Just from a reality check standpoint, there is no way a house the size of ours requires the absolutely largest residential boiler available (there may be some slightly larger but in general, around 200k is as big as they get). Our old boiler does short cycle too, it's loud enough that you can hear it. Even in the dead of winter with single digits at night it cycles on and off. We are probably running somewhere in the 60-70% efficiency range also. Everyone who has quoted for us has universally said "WHOA that's a HUGE boiler for your house." After evaluating all of our options, we are going with a modulating/condensing boiler at about half the capacity (maximum) and putting zones into our house. Right now when it is 68 downstairs, it's about 80 degrees in our bedroom - so at a minimum breaking the house down into different zones for upstairs and downstairs should also help - DH works at home during the day and there is no reason to throw all of that extra heat upstairs when no one is there in order to keep downstairs comfortable. For various reasons we are actually going with more zones than that (the way our system was originally piped makes it extremely easy - labor wise it would be just as much to combine them back into one zone as leave them split - and there is a big temperature difference between the various parts of the house we are splitting off) but you might want to check into whether it is possible given your current piping to separate your 2nd floor from your first into separate zones. Between the zoning and the much more efficient boiler, we hope to slash our energy prices. It's NOT a cheap boiler (the cost of the boiler is more than the cost of your boiler + install) but with our old cast iron radiators with relatively cool return, the condensing part will work great, and with us zoning out our house, the modulating part should work great too (it operates at a much lower BTU if the demand isn't there). It also changes the temperature of the water sent out into the system based on the outside temperature, so if it's 50 degrees outside and we want to maintain say 70 inside, it's not necessarily moving 180-190 degree water through the system, so there is savings there too, especially in the shoulder months. We are switching from oil to gas (it would cost us thousands to replace our oil tanks, the real reason we are replacing the boiler - the oil tanks are not long for this world and because there is no longer outside access to the basement it would be a huge job to get the old ones out in pieces and multiple small new ones in and we decided to put that money into a more energy efficient boiler rather than use the same old boiler and just get new oil tanks) so it will be interesting to see the difference in our energy bills. Anyway it took a ton of research and a bunch of time looking at our system and figuring out what was going on to trace out the various loops we have, but I'm glad we put the time into it. We feel confident with the system we have chosen and hope our house will be far more comfortable and energy efficient for the years to come. Energy prices have nowhere to go but up, unfortunately. We are only planning to do this once so figured we'd do it right the first time. The first couple of contractors wanted to put in either a 200k btu boiler to replace the one we have or a 165kbtu boiler calculated by counting radiator fins. As I said before, some of our radiators have about 3x the capacity actually required for comfort in the room so it's kind of silly to oversize in this way because it's just easier to "replace in kind."

To get a true electric rate, you need to calculate in all the surcharges and adjustments on the bill which can be substantial. If you have a bill from that company, just divide $/kWh and use that figure. Maybe they have a sample bill on their web site that would allow the same thing. Is nat gas available where you live? What kind of shape is the boiler and tank in? The Hudson Valley covers a surprisingly large climate range or is Hudson Valley the name of a burg? No matter, Mike_home's statement about the need for calculations is correct. (Maybe crazy) idea for the pros here, but could the oil boiler be kept used for backup heat with a coil for the forced air? It might be worth considering for three reasons, first, cost could be favorable to electric strips, second, heat could be powered by a small generator in case of outage, third, you could use the oil of domestic hot water if gas is not available.

Just some thoughts on improving your existing setup (it's probably got 20+ years' service life left): 1. Don't use a heating boiler for domestic hot water, especially in the summer. 2. Convert to gas if you're currently burning oil (and be sure to carefully clean heat transfer surfaces). 3. Provide as many zones as you can afford, schedule the temperatures with programmable thermostats; use one circulator with multiple zone valves instead of multiple circulators. 4. Arrange for fire on demand (if you have a cast iron boiler - don't do this with a steel boiler). 5. Provide a reset control to limit boiler temperature when it fires (I always liked Honeywell T475A); install the water sensor in the pipe, don't just strap it to the pipe surface. (This is another one not to do if you have a steel boiler). 6. Put in a stack damper (make sure it works properly). Had a good time with this stuff in my first home, a 1930's semidetached; started with a new Weil-McLain oil fired and went from there, over a 24 year period.