Update on Calco Mix

An Update on 

Calco-Mix

It has come to my attention from several regular users of Calco Mix that there has been high level of stones and pieces of concrete etc. found in Calco. One lady told me that an exploding stone had broken the glass of her stove - that can cost a fair bit to replace depending on the type of stove..

I myself have found a collection of extraneous bits and pieces in my Calco-Mix of late. Some are harmless bits of wood etc.  - others are less benign. Either the agents or those making the mix are quite careless, or could it ever be possible that this EXTRA material is being added intentionally for some reason unknown??

Above is a photo I have just taken showing a collection of rocks and concrete I found in my Calco. The lignite briquette and the 1 Euro coin are there just to show scale. The two brownish stones are that colour because they came out of the fire. Luckily I had discovered the rest before placing them in the fire. That collection represents the use of perhaps 2 to 3 bags of Calco - that is a fair bit of extraneous matter. Apart from devaluing the Calco, there is always the dangers presented by an exploding stone in the fire.

I will reserve final judgement but suffice it to say I have lost some of my enthusiasm for Calco-Mix.



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Review of Cast Iron Stoves Some Pointers

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What to Look for

and What to Avoid

in Cast Iron Stoves

Part 1

There has been such a massive increase in interest in solid-fuel stoves, that it is time for me to review the few pointers that I am aware of regarding what to look for, and what to avoid in a stove.

Most stoves sold in Ireland are made in cast iron. Only a very few are made in steel or in stainless steel, so I will not bother looking in this direction. So for a start let us take a look at the material of stoves itself, in this case Cast-Iron.

 

Above you see a small section of the external cast iron casing of a, three year in use, stove. The coin is only for perspective. Take a close look at the texture of the casting. What do you observe? It looks like a painted surface, but it isn't painted, it is naturally smooth and fine grained, and has not got major sandy texture or more importantly - little holes or pits.

By way of contrast, have a look at the above picture, and ask yourself which of the two examples do you think is the better quality of casting?

In the above very rough textured casting, you should be able to see some pitting. The grain itself is like the surface of a child's sand castle. This very rough grain and the associated pitting effect, are some of the factors that can lead to damage, such as cracking, distortion, and burning away, in a stove. Other factors that can affect the life of the metal of a stove, such as the actual basic material and chemical make-up of the cast iron, you will not be able to see. Regarding the composition of metal, the grates and the baffles should ideally have a chromium content upwards of 12%. Too much chromium will make the metal brittle but with the right amount, it will make it resistant to oxidising, that is distorting and slowly burning away.

Poor Quality Cast = Poor Quality Stove

The vast majority of the problems with stoves, excluding poor design, are associated with the quality of the cast iron that makes up most of the stove. This is especially true of the parts of a stove that come into direct contact with the fire.

Grates and baffles are the most obvious parts that are vulnerable to fire damage. However, some stoves of dubious manufacture, have been known to literally split at the seams. So be warned when shopping for a bargain stove. If you buy a trusted brand name from a trusted retailer, you have at least two lines of come-back in the event of failure.

Look for a good thick and smooth quality of cast iron. Very rough, pitted, or very thin castings are going to lead to problems.

This is part one. I will revisit the subject over the next couple of weeks.



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Blacksmith Stove Review Part 4 - Alert -

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Possible Problems with the

Blacksmith Artisan

I have been doing some close up checking of an installed Blacksmith “Artisan” inset stove. I recon that there are fundamental problems with the level of heat output, and with the hot air convection from the back and sides of the stove

There would appear to be no convection of heat from anything other than the exposed front of the stove. How do I come to that conclusion?

In a normal freestanding stove, heat is dispersed from the back, the sides, and the top of the stove. In the Artisan inset, there are no sides, back or top. The only exposed surface is the front.

If the heat from the sides, back and top of the stove is to be used in the house and not dispersed up the chimney, it would have to be gathered, by air convection, from the hot surfaces of the fire box.

One of the Convection Air intake vents seen on the right  side

Looking at the stove, it would appear to have the necessary features for this convection air flow to happen. It has two air intake slots at floor level either side of the frame which roughly 8 x 4 cm.

Hot Air exit grill on top?? - The Air-Wash damper knob on the right?

It has a large grill, in the frame above the door, which runs the full width of the stove. I would assume that this grill is an exit grill for the hot convection air to get into the room.

Here is the dilemma: 

Air is drawn into both of the intake slots - I checked this with a sheet of paper held near the slots, and sure enough, there is a good flow of air which sucks the paper onto the opening.

In the course of things, you would expect this air flow to be heated around the sides and back of the stove and then to exit as hot air through the slotted vent at the top, wouldn’t you?

But here lies the core of the problem. Instead of an outflow of hot air from the upper grills, air is being sucked in causing a cooling effect. I checked this simply by placing a length of tissue across the top of the grill - it is clearly being sucked in - instead of being gently blown out by the hot air convection.

The airwash damper does not affect the air flow - nor should it - it should have a seperate air way.  So where is all of this air from the room going? What is this telling us?

What appears to be happening is that air is being sucked in both at the top grill, where hot air should be coming out,  and at the bottom air intake slots. This air is effectively cooling the front of the stove and reducing the heat from the one radiant surface.

Poor Heat Output from this stove

The manufacturer rates the stove output at 5 Kw. I have no means of measuring this in any scientific way - but let me say this much, it is well under 3 Kw of heat when compared to a 3 Kw electric heater.

Now, I am hoping that this case might be just a one off problem, and hopefully it does not represent a problem of poor design.

Contacted Blacksmith Stoves

I contacted Blacksmith and had a callback from one of their senior reps. however, he could not directly answer the technical questions, did not seem to understand the principle of the convection process, or of the need for the combustion air and convection air to be completely separate. I was left no wiser by the call.

I have asked for some technical diagrams of the Artisan stove which might clearly show the layout of the airways. I am hoping to have these early next week, and that they will clarify things a bit.

If the convection airways are incorrectly designed and unable to gather heat properly from the back and sides of the firebox, the efficiency of this stove could be no greater than 30% to 40% rather than the 70% claimed. The heat output to the room based on what I experienced is no-where remotely close to the 5 Kw quoted.

I will also request a copy of the independent labs test results, especially the details of the criteria used to determining mean output and fuel to room transfer efficiency.

Best Wait and See

We, that is myself and the owners of the Artisan stoves, will await some technical clarification and assistance, and detailed diagrams and instructions, and I will inform this blog of the outcome.

In the meantime - Caveat Emptor (buyer beware) applies. Personally, if I were considering a purchase or installation of the Blacksmith “Artisan” stove, I would postpone until the design, heat output, and efficiency can be fully assessed.

I will post information as it becomes available.


ADDENDUM:
Added 11th January 2012

I have since received a copy of the standards certification cert of the Artisan stove along with a set of technical drawings showing an exploded view of the stove from the people at Blacksmith. It all looks 100% kosher. As far as I can tell from the drawings, all the bits are there and in the right places.

I acknowledge that I have only closely observed one installation and that any inefficiencies may well be associated only with this one stove and installation.


The bottom line however, as far as this one installation goes, is that the output of this stove is substantially less than a similar size of stove, the Blacksmith  "Anvil", which I have no hesitation in recommending.  I would however put the output of heat from the inset "Artisan" as somewhat disappointing.

I would also point out that I have not so far been able to compare the Artisan inset against similar stoves by different manufacturers.

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