What does the catalytic combustor do in a stove?

Normally, smoke will burn, at a temperature of 1000 F. or higher. Burning a stove this hot would require continuous intense fire and would require a higher wood consumption.

The answer to eliminate this is the catalytic combustor.

Wood smoke gases coming in contact with the catalyst, causes chemical changes to take place. This will then allow the smoke to ignite at temperatures around 500 F. or (260 C.)
This temperature is easily achieved in the firebox of a wood burning stove.
As the wood gases ignite and burn within the catalytic combustor, clean by-products of water vapor (H2O) and carbon dioxide (CO2) are emitted.

What makes a clean burning stove?

Wood smoke is unburned fuel, some of which accumulates in your chimney as creosote while the remainder exits the stack as smoke. The key to reducing air pollution from woodstoves is to burn fuel more completely.

The three main things that make a stove clean burning:

a. How it is designed.

b. How it is installed.

c. How it is operated.

Some stove manufacturers use catalytic combustors to burn fuel more completely while others use a variety of design features such as baffles, secondary combustion chambers, and introduction of secondary air.

EPA-certified stoves offer 70 to 90 percent reduction of particulate matter over the older conventional model stoves. This is based on laboratory testing.

Light-off instructions.

Catalytic stoves require special firing techniques.

Instructions for these techniques will be found in the stove manufacturer's manual. If the manual for the appliance has detailed firing instructions, they should be followed. This is very important for smooth operation of the stove and to the life of the catalytic combustor.

In short, the combustor needs light-off temperature before the by-pass should ever be closed.

A temperature of 500 degrees F. must be focused on the catalytic combustor for as least 25-30 minutes before the by-pass is closed.

This will assure you that the combustor has had ample time to light-off. This is just a rule of thumb for most catalytic stoves.

Remember to read the manufacturer's manual before building the first fire in you stove or contact Applied Ceramics.

Tips on installing a woodburning stove.

DO insulate your existing masonry chimney, especially if it's located on an outside wall.
Why?
Because insulation helps create a proper draft and prevents icing, which can block your chimney.

DO insulate the space between the existing masonry chimney and the flue, but do not use loose pack insulation.
Why?
Because loose packed insulation can enter the flue and block the flue gases.

DO use the manufacturer's recommended flue diameter. For woodstoves vented through an existing masonry fireplace chimney, use solid pack insulated lining to fit the stove flue into the chimney.
Why?
Because an improperly sized flue will not provide the draft needed to operate the stove. Also, smoke may leak into your house through the air inlets without proper draft.

DO make certain that all seals connecting the stove to the flue, and within the flue, are as airtight as possible.
Why?
Because tight seals will prevent smoke from leaking into your house and contribute to good draft.

DO determine the correct amount of draft for your stove. Draft is the force that moves hot gases up through the flue. Draft depends on the length of the flue, local geography, nearby obstructions, and other factors. Consult certified installers and chimney sweeps (they may have draft gauges to measure draft).
Why?
Because too much draft produces an uncontrolled burn and may cause the stove parts to overheat. This can damage the stove. Too little draft will cause "backpuffing" of smoke into the room, or will accelerate the deposit of soot in the stove or flue.

EPA certified catalytic appliances save time and money!

A leading catalytic stove manufacturer quoted as follows:
If the consumer wants:
1. an efficient stove (burns less wood / BTU),
2. a stove that costs less to operate (burns less wood / BTU),
3. a stove that pollutes significantly less at low and medium burn rates,
4. a stove that will easily go 10 to 12 hours on a load of wood without reloading and while not polluting. Then a catalytic stove is a smart choice. One complaint might be that a replacement catalyst can cost the consumer more than $200 in the larger stove models. (4 cu. ft. firebox)Several stove manufactures have stated that a catalyst will save 5 cords of wood per heating season. With that in mind, consider the number of cords you burn each season and the cost of a cord of firewood (you pick a cost) - say $200, $350. Naturally the cost per cord depends on where you live and the type of wood you burn.

Now do some math and look at the savings. Exactly how expensive is something that saves you more than $1,000 per season. And for those who get their firewood free, what was the cost and time required to cut it, load it, move it, store it, dry it and etc.

Point is CATALYST SAVE TIME & MONEY. Also remember, the catalyst in a new EPA certified wood burning stove carries an EPA approved 6 year prorated warranty from the date of purchase of the appliance. The first three years are free replacements should the catalyst go bad for some reason.
After the first 6 years, starting from the date the appliance was purchased, a FIRECAT replacement catalyst can be purchased (if needed) with yet another special prorated warranty.
Call Applied Ceramics 770-448-6888 for complete details or log on to appliedceramics.com and click on Hearth Products.

Can EPA certified stoves save you money?

Yes, For example, if you have a typical unregulated stove and use three cords of wood (at $100/cord) and have three chimney cleanings (at $50 each) per season, you can save about $200 per season by purchasing a new EPA-certified stove.

If the new stove is catalytic, you will save an additional cord of wood out of every three cords you burn each season. (see my 2/08/08 posting on: What are the advantages of using a catalytic wood burning stove?)

Your actual savings will vary according to how often you use your stove and other factors. Nationwide, the net savings from reduced firewood consumption and fewer chimney cleanings is estimated to be $30 million annually. In addition, the health and welfare benefits resulting from fewer smoke-related illnesses and from reduced materials damage is estimated at about $1.5 billion annually.