Hybrid Gas/Wood/Soda Kiln Beachville, Ontario
32 Cu/ft Caternary Arch hybrid kiln with drop down ash pit, brick grate, center hinge pin swing door, and rolling stoke hole doors. We used 9"x18"x3" Seneca 60P for the floor, Alphatherm 43 High Alumina #1 arch, Alphatherm 43 High Alumina walls, Seneca 60P grate and flue, BNZ 2660 for the door, and BNZ 2300 for cold face insulation/sub floor to build this kiln. The arch is 4.5” hard brick, 3” BNZ 2300, 2 layers 6# 1” fiber, chicken wire mesh, 1” of 80 lb scratch coat sanded with fiber stucco/3 gallon vermiculite custom mix for skin coat. Interior dimensions hold 3 stacks, 2x 14×28 shelf stacks, and 10×24 door stack. 3/16”-1/4” mild steel framing ranging from 3” to 5” give this kiln and swing door structural integrity. Rolling stoke hole doors make burning wood easy, and this kiln can burn about 3/4-1 cord of split hardwood in 24 hours. There is an opening at the base of the chimney to add a future kiln to share the existing chimney. We added a smoke reduction and dilution system to the flue, base of the chimney, and vertical baffles. The kiln can be fired with minimal smoke up to 1900, then the post combustion system burns all smoke prior to exiting the chimney for a clean/smokeless emission for the duration of the firing including a long hold. We use several principles to eliminate smoke from the chimney, European baffle chimney, masonry heater design, Japanese Sutemna chamber, passive dampers lower/upper, and jet engine afterburner design. We built the kiln in 8 days, and fired the kiln successfully in 28 hours to Cone 10, burning about 3/4 cords of wood. There are no burners, however we placed the burner ports so they can be added at anytime.