H1C018 Fake Logs/Houck2 (Page 2) - OMNI-TestStockton, Vancouver, Toronto, and in Kentucky. Conros Corporation is based in Scarborough, Ontario with plants in Toronto, California and

anufactured logs have becomevery popular and are widelyused. There are two funda-

mental types that often become con-fused with each other. These arewax-sawdust firelogs that are com-posed of a mixture of petroleum waxand sawdust, and densified firelogsthat are made by compressing saw-dust or wood shavings.

Wax-sawdust firelogs are for useexclusively with fireplaces. Compressed(densified) firelogs are for use primar-ily in wood stoves, but can be used infireplaces as well. Most wax-sawdustfirelogs are sold through mass mer-chandisers and grocery stores. Most com-pressed firelogs are sold through massmerchandisers and fuel dealers. Thedemand for both products is increasing.For densified firelogs, economical dis-tribution and the availability of rawmaterials appear to be the biggest prob-lems facing their manufacturers. Forwax-sawdust firelog manufacturers,regulations limiting the installation anduse of fireplaces are of considerableconcern.

Wax-Sawdust Fireplace LogsWax-sawdust fireplace logs (firelogs)

are a convenient substitute for cord-wood. Surveys have shown that wax-sawdust firelogs are used at least someof the time in about 30 percent ofwoodburning fireplaces that are in usein the U.S. This means thatsome 5.1 million house-holds are familiarwith the product.

The same sur-veys show thatwax-sawdustfirelogs are usedexclusively in12 to 15 per-cent of thesewoodburningfireplaces.Thiswidespread usageis not surprisingwhen the fact thatabout 61 percent of thefireplaces in the U.S. areused for aesthetic purposesrather than primary or supplementalheating is taken into consideration.

These fireplaces are often only usedon special occasions, perhaps several timesper year. Convenience, such as offeredby individually wrapped, easily startedfirelogs, not fuel cost or the absolute

amount of heat provided, is most impor-tant to the consumer at these times.

Even when fireplaces are used forsupplemental heating, the convenienceof firelogs is often an important con-

sideration to the consumersince, according to the

American Housing Sur-vey data, the major-

ity of fireplaces arein suburban orurban settings. Inthese settings,firelog retailersare generallyclose by andoffer cleanly

packaged boxesof fuel.

Wax-sawdustfirelogs are typically

composed of 40 to 50percent petroleum wax

(obtained from petroleumrefineries) with the remaining being

sawdust. Wax-sawdust firelogs aredesigned for one-at-a-time use in fire-places and require no kindling to start.

by James E. Houck and Paul Tiegs

manufactured firelogsh

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The future looks bright for wax-sawdust and densified firelogs.

M

CONVENIENCE

FUELS

ABOVE: Wax-sawdust firelogRIGHT: Wax-sawdust firelog in use

They are individually wrapped and thefire is started by lighting the wrapper.They contain almost twice the heat con-tent of cordwood (15,700 Btus per poundas compared to approximately 8,800Btus per pound for most cordwood),and much less moisture (two percentmoisture as compared to about 20 per-cent for typical cordwood).

There is a standard for perfor-mance and labeling of wax-saw-dust firelogs (UL 2115). Theperformance standard coversaging, spontaneous heating andheat loss rate characteristics.The common log sizes are 6lbs., 5 lbs., and small (2.5 to3.5 lbs.) for four-hour, three-hour and two-hour burn dura-tions, respectively. They burnbest on grates with closelyspaced bars (less than three-inchspacings between bars) rather thanfactory supplied grates typical ofmost fireplaces. They are generallysold individually or in six-packs withtypical prices in the range of $1 to $3per log.

In addition to the standard firelogs,several types of specialty logs have beenproduced. These include logs thatcrackle, replicating the sound of realcordwood burning. The crackling isaccomplished by the addition of vari-ous seeds (analogous to popcorn in con-cept), or mineral products or byproductswith trapped gas pockets which popwhen heated.

Other specialty products haveincluded logs which produce coloredflames by the addition of salts, logswith fragrances added such as used withscented candles, and logs with chim-ney creosote removal additives.

Since both the wax and the sawdustused in the manufacture of the firelogsare byproduct materials, there is a fun-damental and obvious environmentalmerit in using wax-sawdust firelogs.Beyond this fundamental environmen-tal plus, air quality emissions also havebeen demonstrated to be lowered bythe use of wax-sawdust firelogs in lieuof cordwood.

OMNI Environmental Services(OMNI) has conducted air quality stud-ies for the Department of Energy, theformer Firelog Manufacturers Associ-ation, and Duraflame. The results ofthese studies have been published inthe proceedings of Air and Waste Man-agement Association, U.S. Environ-mental Protection Agency (EPA) and

U.S. Department of Energy-sponsoredconferences. The results also have beenfiled with the EPA for use in theirnational emission inventories.

These studies, along with earlier workdone by Shelton Research and the Cana-dian Combustion and CarbonizationResearch Laboratory, have shown thatthe emission of the key air pollutantsof particles and carbon monoxide arereduced by the use of wax-sawdust firel-ogs in lieu of cordwood. The morerecent studies conducted by OMNI alsohave shown that the important air toxiccompounds of formaldehyde, benzeneand polycyclic aromatic hydrocarbons(PAH) are also reduced through the useof wax-sawdust firelogs.

There has been considerable con-solidation among companies manufac-turing wax-sawdust firelogs. Currentlythe overwhelming majority of wax-sawdust firelogs are manufactured byonly two companies – Duraflame andConros Corporation. Duraflame is basedin Stockton, California, with plants inStockton, Vancouver, Toronto, and inKentucky. Conros Corporation is basedin Scarborough, Ontario with plants inToronto, California and Texas.

Besides logs manufactured under itsown label, Duraflame produces the brandnames of Hearthfire and Flame-Glo, aswell as various private label logs. Con-ros sells logs with the brand names ofNorthland, Hearthlogg and Pine Moun-tain, and private label logs as well.

Surveys have shown that approxi-

mately 253,000 tons of firelogs are soldannually in the U.S. Most are sold inthe West and South. Due to the factthat firelogs contain more heat per poundthan cordwood, less moisture than cord-wood, and are designed for one-at-a-time usage, the 253,000 tons soldannually in the U.S. corresponds to

over one million cords of wood thatare replaced through their use.

Densified LogsDensified firelogs are funda-mentally unlike wax-sawdustfirelogs in manufacture, useand distribution. Far fewerdensified firelogs are producedannually than wax-sawdustfirelogs. It is estimated thatonly 52,000 tons of densified

firelogs are produced annuallyas compared to 253,000 tons of

wax-sawdust firelogs. Densifiedfirelogs are a western phenomenon,

with all operating plants located inthe Northwest (Oregon, Washington,Idaho, Montana and British Columbia)and virtually all sales in the West. His-torically, there have been numerousplayers that have gone in and out ofthe business. Currently, there are eightcompanies that the authors were ableto identify that manufacture the logs.

Densfied firelogs are composed ofcompressed sawdust or wood shavings,generally without any binder added. Thereare two types of technologies used tomake them – piston and screw machines.The original logs were developed in theearly 1930s by Potlatch Corporation inLewiston, Idaho. During their early devel-opment the name “Pres-to-Logs” wascoined. It is currently the name brand oflogs produced by Lignetics but, like theuse of the brand name “Coke” to gener-ically apply to cola soft drinks, theterm“Pres-to-Logs” is often used in thesame way to apply to densified firelogsin general.

Densified firelogs are, as the nameimplies, more dense than wood. In fact,they are so dense, they sink in water.Because they are made up of wood alone,their heat content per pound is the sameas cordwood (on a dry basis). However,they are a superior fuel as their heat con-tent per volume is much greater, andthey contain considerably less moisturethan typical cordwood (densified firel-ogs generally contain about seven per-cent moisture as compared to 20 percentfor typical cordwood).

There are three sizes currently man-

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ufactured – 8, 5 and 3.1 pounds. Thelarger-sized logs are serious fuel andare almost exclusively used in woodstoves. The smaller-sized logs are moreamenable for use in fireplaces but, aswith the larger-sized logs, they are alsomore commonly used in wood stoves.Due to their density, they are more dif-ficult to start than either cordwood orwax-sawdust firelogs. To mitigate thisproblem, Lignetics includes a waxed“mini-log” fireplace starter with bun-dles of their product.

The densified firelogs are generallysold in mass merchandise stores in smallbundles of three or six logs, and by thepallet (about one ton) via fuel dealers.The cost per five-pound log in the smallbundles is around 50 cents per log. Thecost per pallet (ton) is in the $150 to$175 range. Like wax-sawdust firelogs,densified firelogs offer convenience.They are clean and, because of theiruniform dimensions, easy to store.

OMNI has conducted research, spon-sored by the Department of Energy, onair quality emissions from the use ofdensified firelogs. Two studies wereconducted. One was conducted on bothcertified and noncertified wood stovesin use in homes. The other was con-ducted with wood stoves and fireplacestested in the laboratory. The results ofboth studies showed significant reduc-tions in emissions of particles and car-bon monoxide through the use ofdensified firelogs as compared to cord-wood. It is believed that these reduc-tions are due in part to their higherdensity, lower moisture and uniformshape, and in part because they aremade with clean sawdust or wood shav-ings without bark or debris.

Research FormulationsOver the last decade there have been anumber of attempts to make artificiallogs from a variety of biomass andrelated materials. OMNI alone has beeninvolved in the performance and envi-ronmental testing of logs containinggrass seed straw, rice straw, junk mail,cardboard, waxed cardboard, coal dust,olive pits, hazel nut husks, almond shells,palm boughs, peat, molasses, seaweed,palm oil, and polyethylene plastic. Manyof these components are used as “exten-ders” for the traditional ingredients indensified or wax-sawdust firelogs. Someof the formulations have been com-mercialized on a limited basis. Eitherway, the use of biomass wastes or by-products for fuel offers an attractive

and obvious environmental benefit.

Packaged FirewoodPackaged firewood (bundled or boxed),while not a manufactured fuel, appealsto the same consumers for the samereasons as manufactured firelogs, andis also sold at mass merchandiser out-lets and grocery stores. Quality fire-wood supplied by reputable dealersshould produce lower air emissions thantypical cordwood since it is generallybetter-seasoned, i.e., has lower mois-ture (10 to 12 percent as compared toaround 20 percent for typical cordwood),contains no bark and is clean of debris.Proponents of its use point out that thesmell and crackle of natural firewoodare aesthetically more pleasing than thatproduced by manufactured fuels andthat, importantly, the heat provided perunit cost (Btu/$) for firewood is higherthan for manufactured fuels.

While variable, the average packageof firewood weighs around 24 poundswith a cost in the $4 to $6 range. Notsurprisingly, unlike manufactured fuelswhich require capital intensive equip-ment, there are many small entrepre-neurs in the business since all that isreally required is a wood source, a truckand cutting/splitting equipment. To pro-vide a sense of scale, in California alonethere are at least six major dealers andinnumerable “mom and pop” operationswhich combine to provide an estimated70 thousand tons of packaged firewoodannually.

The FutureThe future should be bright for biomassfuels in general and manufactured fuelsin particular. The rising costs of fossilfuels for residential space heating willonly increase the demand for densifiedfirelogs for fuel. The concern over pos-sible power shortages has had the under-standable effect of manufactured fuelstockpiling by consumers. The increas-ing number of fireplaces due to newhome construction should make forincreased sales of wax-sawdust firelogsand, to some extent, densified firelogsas well.

There are about 600,000 new fire-places installed annually in the U.S. Ifthe ratio of woodburning to gas fire-places, and the fraction of woodburningfireplaces that use wax-sawdust firelogsare the same for new fireplaces as forexisting ones, this corresponds to approx-imately 82,000 new fireplaces that willuse wax-sawdust firelogs annually.

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Densified Log Manufacturers

Bear Mountain Forest ProductsCascade Locks, OR

(541) 378-8844

Dellen Wood LogsSpokane, WA(509) 928-1397

Eureka Pellet MillsMissoula, MT

(406) 543-0812

Home Fire Prest Logs, Ltd.Surrey, BC

(604) 530-8078

LigneticsSandpoint, ID(208) 263-0564

North Idaho Energy LogsMoyie Springs, ID

(208) 267-5311

Sawtooth Forest IndustriesMelba, ID

(208) 495-1200

West Oregon Wood ProductsColumbia City, OR

(503) 397-6707

Wax-Sawdust Log Manufacturers

Conros CorporationScarborough, ON

(416) 751-4343

DuraflameStockton, CA (209) 461-6600

manufactured firelogs

In terms of densified firelogs, theonly limitation to sales in the Westappears to be available fiber. Consumerproduct familiarity and economics appearto be the major issues associated withthe expansion of densified firelog man-ufacture and sales to the rest of thecountry. Economic issues include thestart-up costs for new plants orshipping from the West, as bal-anced against low-cost localcordwood. In addition, many ofthe same companies that man-ufacture or could manufacturedensified firelogs also manu-facture pellets, which competefor the same fiber resources.Raw material availability, whilenot yet limiting the manufac-ture of wax-sawdust firelogs, isalso of continual concern to thatindustry, and much of their researchand development activity is testingnew raw materials.

Environmental issues are a “doubleedged sword.” Restrictions against theinstallation or use of woodburning stovesor fireplaces have the obvious effect ofreducing the number of opportunitiesfor home occupants to burn manufac-

tured fuels. Classic examples of thissituation are Maricopa County, Arizona,and communities in and around the Bay

Area of California. On the other hand,the fact that manufactured fuels havebeen documented to produce lower emis-

sions can provide an impetus for theiruse. Continued public education andinteraction with regulators will berequired to increase use commensu-rate with environmental benefits.

For More InformationFor more information on wax-sawdust

firelogs, contact Chris Caron, vice pres-ident of marketing for Duraflame –

209-461-6600.

For more information on densifiedfirelogs, contact either ChristopherSharron, president of West Ore-gon Wood Products – 503-397-6707 or Ken Tucker, president ofLignetics – 208-263-0564.

For information regarding packagedfirewood, contact Les Scott, CEO of

California Hot Wood – 209-333-5480.

For information on safety testing, contactRichard Sparwasser, vice president of OMNI-Test Laboratories – 503-643-3788.

For information on firelog environmental orperformance testing and product develop-ment, contact the authors Paul Tiegs or JamesHouck – 503-643-3788.

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National 253 52

Northeast 27 0

Midwest 23 0

South 94 0

West 109 52

WAX-SAWDUST DENSIFIED LOGS

Tons (in thousands) Firelogs Sold in

the U.S. by Region.