Hmmm. I've got the original ceramic in my 'stone right now. It's probably into its third full season...hard to say since I've run a couple other stoves in the interim. I have also run a diesel-foil in the Keystone, so if I go back to it soon I'll have to take note if it drops out much sooner than the ceramic. I haven't run a DuraFoil yet...
Yeah, I wonder about the price difference. Do they use more catalyst wash coat in the steel, higher mfg. cost, or what? ,If as webby said, the steel lights quicker but also drops out quicker, you'd think efficiency and emissions might be a wash. Have you hear BKVP or anyone say anything about steel vs. ceramic?
I certainly wasn't too thrilled to see this in the Applied Ceramics (OE) that I got for the Buck 91...wash coat looks a bit scant. What do I know though....you really can't see coverage as well when you look at a steel cat. Can't remember if I got that one from Buck, AC, or some other supplier...
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If it just cracks, but all the smoke still has to pass through it, you are OK. Just go out and look at the plume after you close the bypass; You should see no smoke...only heat or maybe some steam. It's about emissions
and heat. You ain't gonna get your heat out of an EPA stove, cat or non, or get the heat out of your fuel, if you don't burn the smoke. Not to mention, it's illegal to operate the stove without the cat.