Understand the Combustor and Appliance work together

Understanding the catalytic combustor is as important as understanding how to operate the stove.

In other words, if the stove is operated correctly, than the catalytic combustor will operate correctly as well. 

Every catalytic stove purchased by the consumer comes with an operating manual explaining how to operate the appliance.
It is very important that the consumer read this information before building the first fire in their new appliance.

Every FIRECAT replacement catalytic combustor sold to the consumer by Applied Ceramics includes a brochure explaining everything they should know about the combustor.

Applied Ceramics has a website with combustor information to help the consumer with any questions.

Applied Ceramics also has a courteous staff of service personnel to help consumers with any catalytic combustor questions.

Applied Ceramics has a four segment video posted on this blog site’s home page, which contains information about catalytic combustors.

EPA certified woodstove labels

All certified woodstoves offered for sale will have a permanent and a temporary label indicating that the stoves are EPA-certified. The temporary label will also contain information that you will find useful when shopping for a new stove.

The label will tell you generally how clean and how efficient each woodstove is. However, because regulations require all new stoves to burn much cleaner and more efficiently than unregulated woodstoves, there should not be significant differences in efficiency and emissions performance among the certified catalytic models. This holds true for the non-catalytic models as well.

The label will also indicate which stoves are equipped with catalytic combustors.

Perhaps the most important information on the label you will need when selecting a stove is the heat output range. Use this information to help select the right size stove for the space you will be heating.

Sample temporary labels:  



Why wood stoves are certified

Residential woodstoves are one of the nation's largest sources of particulate matter (smoke). Wood smoke also contains significant amounts of carbon monoxide, hydrocarbons, and many other organic compounds. These pollutants are known to cause respiratory and cardiovascular illness and contribute to atmospheric visibility problems and property damage. The EPA regulations require woodstove manufacturers to produce stoves that emit less pollution.

 As consumers replace their older woodstoves with cleaner, more efficient, new stoves, the quality of the air will improve, particularly in residential neighborhoods where wood burning stoves are popular.

Be sure and ask your local stove dealer about the high efficient, clean burning catalytic stoves and watch for my future articles on "Buying an EPA-Certified Woodstove"

Catalytic woodstove technology

It was best stated back in the 1988 September issue, of one of the industry's leading magazines... and I quote word for word from the article: The article reads: The EPA is on record stating catalytics represent the "best demonstrated technology" the industry has today. In other words, it's the federal agency's policy that combustors are the best solution to the wood smoke problem.
The EPA points to the following factors:
-More than 60 manufacturers use combustors in their stove designs.
-Catalytics deteriorate, but the EPA figures consumers can expect to squeeze more than 10,000 hours out of the combustor.
The deterioration of combustors is an improvement point, because the agency compared the lifetime performance of catalyst and non-catalyst units.
They note that catalytics burn cleaner than non-cats during a stove’s early years.
However, the emissions put out by a catalytic stove increases as the combustor ages. Both types of units burn about as clean, when averaged over the lifetime of the stoves, according to the EPA.(end of article)
This is why the EPA's Phase I and Phase II emission limits, on wood burning stoves, are set the way they are.
However, catalytic stove technology has came a long way since this article was written.
Catalytic stove designs have changed since 1988. The catalytic combustor is now well protected from firebox flames in all catalytic stove models.
I would like to add this comment:I have talked to consumers over the years, that had catalytic units that held up for 10 to 15 years and were still working on the day they called me.Easy to see why FIRECAT combustors are offered to consumers with a 6 year prorated warranty from the date they buy a new catalytic stove. 
A few more related comments:1. FIRECAT catalytic combustors are made of high temperature, honeycomb ceramic and will take up to 2400 degrees F. before they reach, what I call a glazing point. Naturally, the stove will never reach this kind of operating temperature to destroy the combustor. They are durable and hold up well under proper operating methods. Flame impingement and thermal shock, not normal operating methods, can be another story altogether. This will be addressed at a later date.
2. FIRECAT combustors are coated with noble metals that act as the catalyst. They never go away or wear out. Only ageing, abuse or improper operating of the stove will stop them from doing their job. 
3. FIRECAT combustors can save the stove owner a lot of money over the years. Consider fuel costs alone. (as much as 1 less cord out of every 3) By burning low, they will save on fuel costs and best of all with no sacrifice of BTU output.
The FIRECATThe FIRECAT combustor will produce temperatures that are at least twice that of the firebox. Therefore, they don't need high flames in the firebox to produce heat to keep warm. Check out the catalytic stove's efficiency and do some comparing.

How can I tell if a woodstove is EPA-certified?

All certified woodstoves offered for sale will have a permanent and a temporary label indicating that the stoves are EPA-certified. The temporary label will also contain information that you will find useful when shopping for a new stove.

The label will tell you generally how clean and how efficient each woodstove is. However, because regulations require all new stoves to burn much cleaner and more efficiently than unregulated woodstoves, there should not be significant differences in efficiency and emissions performance among the certified catalytic models. This holds true for the non-catalytic models as well.

The label will also indicate which stoves are equipped with catalytic combustors.

Perhaps the most important information on the label you will need when selecting a stove is the heat output range. Use this information to help select the right size stove for the space you will be heating.

Example temporary labels: 

Why does the U.S. EPA regulate woodstoves?

Residential woodstoves are one of the nation's largest sources of particulate matter (smoke). Wood smoke also contains significant amounts of carbon monoxide, hydrocarbons, and many other organic compounds. These pollutants are known to cause respiratory and cardiovascular illness and contribute to atmospheric visibility problems and property damage. The EPA regulations require woodstove manufacturers to produce stoves that emit less pollution.

 As consumers replace their older woodstoves with cleaner, more efficient, new stoves, the quality of the air will improve, particularly in residential neighborhoods where wood burning stoves are popular.

Be sure and ask your local stove dealer about the high efficient, clean burning catalytic stoves and watch for my future articles on "Buying an EPA-Certified Woodstove"

Why catalytic stoves are required to have lower emission limits.

It was best stated back in the 1988 September issue, of one of the industry's leading magazines... and I quote word for word from the article:

The article reads:
The EPA is on record stating catalytics represent the "best demonstrated technology" the industry has today. In other words, it's the federal agency's policy that combustors are the best solution to the wood smoke problem.
The EPA points to the following factors:
-More than 60 manufacturers use combustors in their stove designs.
-Catalytics deteriorate, but the EPA figures consumers can expect to squeeze more than 10,000 hours out of the combustor.
The deterioration of combustors is an improvement point, because the agency compared the lifetime performance of catalyst and non-catalyst units.
They note that catalytics burn cleaner than non-cats during a stove’s early years.
However, the emissions put out by a catalytic stove increases as the combustor ages. Both types of units burn about as clean, when averaged over the lifetime of the stoves, according to the EPA.
(end of article)

This is why the EPA's Phase I and Phase II emission limits, on wood burning stoves, are set the way they are.
However, catalytic stove technology has came a long way since this article was written.
Catalytic stove designs have changed since 1988. The catalytic combustor is now well protected from firebox flames in all catalytic stove models.

I would like to add this comment:
I have talked to consumers over the years, that had catalytic units that held up for 10 to 15 years and were still working on the day they called me.
Easy to see why FIRECAT combustors are offered to consumers with a 6 year prorated warranty from the date they buy a new catalytic stove.

A few more related comments:
1. FIRECAT catalytic combustors are made of high temperature, honeycomb ceramic and will take up to 2400 degrees F. before they reach, what I call a glazing point. Naturally, the stove will never reach this kind of operating temperature to destroy the combustor. They are durable and hold up well under proper operating methods.
Flame impingement and thermal shock, not normal operating methods, can be another story altogether. This will be addressed at a later date.

2. FIRECAT combustors are coated with noble metals that act as the catalyst. They never go away or wear out. Only ageing, abuse or improper operating of the stove will stop them from doing their job.

3. FIRECAT combustors can save the stove owner a lot of money over the years.
Consider fuel costs alone. (as much as 1 less cord out of every 3)
By burning low, they will save on fuel costs and best of all with no sacrifice of BTU output.
The FIRECAT combustor will produce temperatures that are at least twice that of the firebox. Therefore, they don't need high flames in the firebox to produce heat to keep warm.
Check out the catalytic stove's efficiency and do some comparing.

Particulate matter emissions

Standards for particulate matter emissions under the EPA’s Phase II Program

Unless exempted under §60.530 of the U.S. EPA Federal Register, each wood burning appliance manufactured on or after July 1, 1990, or sold at retail on or after July 1, 1992, shall comply with the following particulate matter emission limits as determined by the test methods and procedures in §60.534 of the U.S. EPA Federal Register:

A wood burning stove equipped with a catalytic combustor shall not discharge into the atmosphere any gases which contain particulate matter in excess of a weighted average of 4.1 g/hr (0.009 lb/hr).

A wood burning stove not equipped with a catalytic combustor shall not discharge into the atmosphere any gases which contain particulate matter in excess of a weighted average of 7.5 g/hr or (0.017 lb/hr).

Exempt from EPA certification

Wood burning appliances exempt from EPA certification  (Subject to future changes)

1. Stoves built by U.S. manufacturers for export and not sold in the United States.
2. Boilers. (Certification program to start in March of 2008)
3. Furnaces.
4. Cook stoves.
5. Stoves for coal burning only.
6. A wood heater built for research and development purposes.
(Not to be sold and no more than 50 per model)


Definitions of appliances exempt from EPA certification…

Boiler…Boiler means a solid fuel burning appliance used primarily for heating spaces, other than the space where the appliance is located, by the distribution through pipes of a gas or fluid heated in the appliance. The appliance must be tested and listed as a boiler under accepted American or Canadian safety testing codes. A manufacturer may request an exemption in writing from the Administrator by stating why the testing and listing requirement is not practicable and by demonstrating that his appliance is otherwise a boiler.

Furnaces… Furnace means a solid fuel burning appliance that is designed to be located outside of ordinary living areas and that warms spaces other than the space where the appliance is located, by the distribution of air heated in the appliance through ducts. The appliance must be tested and listed as a furnace under accepted American or Canadian safety testing codes unless exempted from this provision by the Administrator. A manufacturer may request an exemption in writing from the Administrator by stating why the testing and listing requirement is not practicable and by demonstrating that his appliance is otherwise a furnace.

Cook stoves… Cook stove means a wood-fired appliance that is designed primarily for cooking food and that has the following characteristics:
(1) An oven, with a volume of 0.028 cubic meters (1 cubic foot) or greater, and an oven rack,
(2) A device for measuring oven temperatures,
(3) A flame path that is routed around the oven,
(4) A shaker grate,
(5) An ash pan,
(6) An ash clean-out door below the oven, and
(7) The absence of a fan or heat channels to dissipate heat from the appliance.

Coal burning heater… Coal-only heater means an enclosed, coal-burning appliance capable of space heating, or domestic water heating, which has all of the following characteristics:
(1) An opening for emptying ash that is located near the bottom or the side of the appliance,
(2) A system that admits air primarily up and through the fuel bed,
(3) A grate or other similar device for shaking or disturbing the fuel bed or power-driven mechanical stoker,
(4) Installation instructions that state that the use of wood in the stove, except for coal ignition purposes, is prohibited by law, and
(5) The model is listed by a nationally recognized safety-testing laboratory for use of coal only, except for coal ignition purposes.

What are the advantages of using a catalytic wood burning stove?

An EPA Phase II catalytic wood burning stove delivers 72% or better heating efficiency. This means that 72% of the energy available in wood is delivered into the surrounding living area.

In addition to the 72% heating efficiency, the catalytic wood burning stoves of today:

1. Reduce air pollution by up to 90%.
2. Reduce creosote build-up. (Up to 90% reduction)
3. Generate up to 50% more useful heat from each log.
4. Generate longer burns per load.
5. Saves the consumer up to 1/3 on fuel cost. (One less cord out of every 3)

EPA Stove Phases defined:

Pre-Phase I stoves…These stoves could not be manufactured after June 30, 1988.
However, stoves could be sold at retail level for two more years.

Phase I program…. went into effect on July 1, 1988 and was effective through June 30, 1990.
Manufacturers could not build stoves after this dead-line.
Again, these stoves could be sold at retail level for two more years.

Phase II program… went into effect on July 1, 1990 and is effective still today.
Manufacturers must re-certified all models every 5 years under the Phase II program.

A New Era for the woodburning stoves.

In the early 1980’s, it was reported, better than 500 manufacturers were building wood burning stoves. Many were just one man operations, designing and building their stoves in the garages of their homes.
However, it wasn’t long before the Oregon DEQ and US EPA put a halt to just anyone building and selling wood burning stoves. New regulations, standards, and certification programs forced many of the smaller companies out of this type business. This was mainly because they could not meet the new regulations or could not afford the expense to comply. On the other hand, the larger stove manufacturers could afford the expense to comply and remained in business.
It was at this point in time, catalytic combustors played a major role in the survival of many stove manufacturers.

In 1988 one of the industry magazines published an article entitled “A NEW SEASON FOR WOODSTOVES”. Another article written by the US EPA entitled “EPA and You” talked favorably about catalytic combustors and stated, “Expect to see many more of these types of wood burning appliances in coming years”. 

Another article published in the September issue, reported more than 120 wood burning stoves had been EPA certified and nearly two-thirds were catalytic units.
By the end of 1989, there were nearly 80 woodstove manufacturers certified to at least the EPA’s Phase I emissions program and 60% of these manufacturers had certified with catalytic wood burning appliances. Some of their catalytic models had emission ratings as low as 1.0 gph and 72% efficiency. The catalytic models had less fuel consumption and creosote reduction of up to 90%.
After June 30, 1990 stove manufacturers could no longer build the Phase I stoves and now had to build stoves to meet the EPA’s Phase II program.
Six months after the Phase II certification went into effect, roughly 70 woodstove manufacturers were already certified to the Phase II program.
Of these 70 stove manufacturers, 41 were certified with catalytic models. This was 58.6% of the stove manufacturers to this point in time. The 1990’s proved to be a super sales year for the manufacturers building catalytic stoves and the dealers selling them.
Throughout the decade magazines published articles about catalytic stoves and the catalytic combustors in them. Articles like, “Keeping Cats Purring”
Articles from dealers and chimney sweeps stating “it is important to remember, that people who buy catalytic products are generally those who are interested in the best possible performance and have greater heating needs” and a chimney sweep in the state of Washington saying, “In general, cats three to five years old are holding up well” and another sweep in North Carolina stating, “He hasn’t had a service call for a combustor during the two years he’s been servicing and selling EPA approved catalytic stoves”.
The catalytic wood burning appliances had established a place in the industry and in the hearts of the consumers using them.

History of the Catalytic Combustor

Understanding the catalytic combustor’s role in the wood burning stove industry, requires us to look back to the 1970’s when heating costs increased drastically. Oil prices increased 272% in that decade; electric rates increased 215%, while natural gas increased 483%.
To combat these cost increases, many homeowners began to switch to wood as a fuel for their heating needs.

This was less costly and besides firewood was free and plentiful in many areas.

Hundreds of new stove companies began to spring up. Many of them building stoves with efficiency ratings between 50 and 70%. This was as good as or better than gas furnaces and oil burners.

However, the advantages of burning wood for heating were also accompanied with some disadvantages.
-Much wasted energy was lost in the smoke. (30% in some stoves)
-The smoke from wood-burning fires produced harmful air pollution.
-Airtight stoves burning slow produced heavy amounts of creosote.

It was in the early 1980’s that the catalytic combustor was found to be an ideal solution aimed at answering consumer, manufacturing and environmental problems.
The U.S. EPA and DEQ later set standards for the stove manufacturers to follow and a new era in wood burning began.

Catalytic combustors and catalytic wood burning appliances.

Starting Monday January 7, 2019

I will begin posting articles on catalytic combustors and catalytic stoves in a manner that will allow a better understanding of catalytic combustors and catalytic wood burning appliances. 

I will start by covering the history that lead up to these modern day appliances and why they became so popular.

If you’re thinking about buying a new catalytic appliance, you will understand why they are such a good buy and you will also understand how simple they are to operate. 

Why am I doing this?  Because I have spent 30 years working with wood stove manufacturers, independent stove testing companies and with the U.S. EPA in the wood burning stove industry.  I have spent countless hours working with consumers, dealers and distributors as a sales engineer for Applied Ceramics Inc., the leading manufacturer of catalytic combustors for wood burning appliances.  I am retired now and want to continue educating people on what I feel is the best heating value for their money.  I too am a consumer and I want the truth when buying a product.  I want the same for you and I have no reason to feed you false information, just the facts.

Please stay with me through the year as I post articles every three days on understand everything you should know about catalytic wood burning.