Happy New Year from APPLIED CERAMICS INC.

Happy New Year.  I sincerely hope the new year will bring you much happiness and the best of health.

Need a replacement combustor?

If you need a replacement combustor, I strongly recommend calling the friendly sales people at Applied Ceramics Inc. 

You can also order your need online.

Applied Ceramics has the size you need and can get it to you fast.

Use the information on my home page and contact them today.

Important information about the Catalytic Combustor.

Most catalytic combustors used in manufacturing catalytic stoves today are made of a high temperature, honeycomb patterned ceramic substrate.
They are coated with special noble metals like palladium and/or platinum.
The honeycomb pattern gives the combustor surface area for the catalytic coatings.

Note:  I would like to point out that cell density (16 or 25 cpsi) plus the combustor dimensions are both very important to the stove’s operation.  The stove was designed and certified for best efficiency using a catalytic combustor having these features.

1. Open frontal area of the combustor is designed to receive the flow rate of the gases coming from the firebox.
2. The combustor’s size and cell density will control the residence time needed for the gases to burn within the combustor.

Always replace the stove’s combustor, when needed, with the original OEM combustor size and cell density for best efficiency and performance of the stove.

Reasons for smoke spillage.

<sup>A survey of households that use wood for heating showed that a large majority of users had experienced smoke spillage at least once. Smoke spillage can be reduced or eliminated through good system design and proper appliance operation.
The smell of wood smoke can be pleasant to some, but inside your home it’s a sign that the wood burning system is not functioning properly. The smoke contains harmful air pollutants which can be irritating or even dangerous in high concentrations. Properly designed, installed and operated wood burning systems do not spill smoke into the house.

There are three main reasons why some wood burning systems smoke:

1. Bad system design: There are design characteristics that can make a wood burning system more likely to spill smoke. Most of these characteristics result in low flue temperature and low draft. Outside wall chimneys and long flue assemblies before exhaust reach the chimney are just a couple.

2. Extreme negative pressure in the house: Energy efficiency practice and new building code rules are making our houses more and more air tight. This makes the house energy efficient, but also makes them sensitive to depressurization when air is exhausted from the house. Other exhaust appliances used in the house can cause extreme negative pressure in the house when they are operating.

3. Improper woodstove firing technique: When a wood fire is starved for air it smolders, producing a relatively cool, smoky fire. The temperatures throughout the system are low. During a smoldering fire, the chimney will not be receiving the hot gas it needs to produce strong draft.</sup>

^{And remember, when refueling first open the by-pass before opening the firebox door.}

Techniques on Fueling

Techniques for fueling may vary, but shown below are the two most common.

Small pieces of wood arranged loosely in a crisscross pattern burn quickly because the combustion air can reach all the pieces at once.

Larger pieces placed compactly burn more slowly because there are fewer spaces where the air can penetrate the load.

Never add just one or two pieces of wood to a fire. Three or more pieces are needed to form a sheltered pocket of glowing coals that reflect heat toward each other and sustain the fire.

How to rekindle a fire from hot coals.

To rekindle a fire from hot coals, rake the charcoal towards the front of the firebox where the combustion air enters. Place the pieces of wood on and behind the coals. Open the air intakes fully and leave them open until the pieces of wood are well-charred. 

The above illustration shows the arrangement of logs for an extended fire.

Allow the fire to burn with bright turbulent flames until the wood is burning well. This should take about 20 to 30 minutes, depending on the size of the pieces and the moisture content of the wood. If the appliance is catalytic, this will also be ample time for the catalytic combustor to light-off. Now the by-pass can be closed and the air intakes regulated for a nice even burning fire.

Be sure to read the stove's operating manual for complete instructions.

How to maintain catalytic burning conditions

When initially starting up a cold stove, a medium to high firing rate must be maintained for approximately 20 to 30 minutes.  This will allow the stove, the catalytic combustor and the fuel to stabilize at a proper operating temperature. Even though temperature can reach 600^o f. within a few minutes after the fire has started, if the fire is turned down to soon to a low burning condition, it will result in the fire and/or the catalytic combustor going out.

At the end of a burn cycle, it’s possible that the amount of burning charcoal remaining might not provide sufficient temperature or fuel for the catalyst to stay lit.

During the refueling of a hot stove that has an internal temperature below 500^o f., it is best to fire the stove up for 1o to 15 minutes to ensure sufficient temperature and proper amounts of volatile gases for the catalyst to operate well and efficiently. 

However, when refueling a hot stove that has an internal temperature above 500^o f., no re-firing is necessary.

Starting a cold catalytic wood burning stove.

^{As a rule of thumb, when starting a fire in a cold stove, the combustor must have 500 o F. of temperature focused on it for 20 to 30 minutes to achieve proper light-off.
The by-pass should be in the open position during this period of time.
This will allow the stove, the catalytic combustor and the fuel to stabilize at a proper operating temperature.
Even though temperature can reach 600 degrees F. within a few minutes after the fire has started, if the fire is turned down too soon to a low burning condition, it will result in the fire and/or the catalytic combustor going out.
At the end of a burn cycle, it’s possible that the amount of burning charcoal remaining might not provide sufficient temperature or fuel for the catalyst to stay lit.
During the refueling stage, if the stove’s firebox has an internal temperature below 500 o F., it is best to fire the stove up for 10 to 15 minutes.
This will provide increased temperature and proper amounts of volatile gases for the catalyst to operate efficiently.
However, when refueling a hot stove that has an internal temperature above 500 o F., no re-firing is necessary.
Refer to the manufacturer's stove operating manual for complete details.}

Is it all right to 'hot fire' a catalytic stove?

Do not "hot fire" your catalytic stove with the by-pass closed.

If this is done with the by-pass damper closed, flames will be directed to the catalytic combustor and cause damage to it.
For many years retailers and installers have advised customers to build an extra hot fire to burn the creosote deposits in the flue system.
This advice is harmful to a catalytic stove and the combustor.
Why not? Because the catalyst is reducing the particulate, or creosote build-up, therefore the need to hot fire for this purpose is eliminated.

Why is it important to select the correct replacement combustor for your stove.

Please remember this very important information....

Cell density (16 or 25 cpsi) plus the combustor dimensions are both very important to the stove’s operation. The combustor's size and cell density was designed into the stove by the stove's manufacturer for best performance.

1. Open frontal area of the combustor is designed to receive the flow rate of the gases coming from the firebox.

2. The combustor size and cell density will control the residence time needed for the gases to burn within the combustor.

Always replace the stove’s combustor, when needed, with the original OEM combustor size and cell density for best efficiency and performance of the stove.

Operating the catalytic appliance and the combustor inside.

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.

Have a great day

Firecat combustors are made to manufacturer's specifications.

  FIRECAT COMBUSTORS

Catalytic combustors are manufactured by Applied Ceramics to a stove manufacturer's specifications. 

Each combustor requires a certain cell density to allow the stove a proper flow rate of the gases.

They are designed to allow proper residence time for the smoke and gases to burn before exiting the stove.

They are also sized based on the firebox volume.

All catalytic combustors must be EPA approved to assure the consumer they not only work, but will meet EPA emission regulations.

Once again, Applied Ceramics Inc. manufactures and stocks a complete line of all catalytic combustors.