posted 5 days ago
It might be possible to construct a 5-channel contraflow insert to fit in the available space. This sounds like a very tricky proposition, however.
I am currently working through Axel Berberich's online course/tutorial (offered through Bosco di Ogigia) on building a pyrolyzing gasifier stove, using homemade precast refractory parts (and some metal bits, too). My primary interest in his course is that he discusses somewhat peripherally the conversion of wood cook stoves to gasifier burners. Old wood burning cook stoves in serviceable (if not pristine) condition are typically available in my area for between 100 and 200 USD, but sometimes can be had free for the hauling (I got a kitchen end heater that way - rolled it away on an appliance dolly!). Anyway, I would suspect that you could, with care, make up molds for pieces to fit up into the existing fireplace's firebox and smoke chamber to define the contraflow channels. Axel recommends a mix of high alumina refractory cement and vermiculite for the precast pieces. One time molds might be made from scraps of wood, sheet metal flashing, cardboard mailing tubes or sonotubes, etc. He glues the pieces together with a mix of fire clay and sand, similar to how most thermal mass heaters made from bricks are mortared together. But, is all of this worth it? I don't know. It would be a reversible conversion, though, if done with care, so might do minimal if any violence to the architectural integrity of the house.
Another thought would be to make a firebox insert which converts it into more of a radiant fireplace, Rumford style. That might be easier, and should get more heat out into the room. There are lots of modern interpretations of Count Rumford's fireplace. My recommendation is to chase down his book (I have found it on Archive,org in the past), give that a read, then see what some of the modern proponents have to say about it. At least you'll understand the problem he was trying to solve (not so different from your inefficient fire place) and what he did to improve matters, and you can better assess the modern versions. You could pre-cast some Rumfordizing parts, too, though fitting the traditional lintel and throat into the Kiva style fireplace might also be tricky.
"Ah, but a man's reach should exceed his grasp,
Or what's a heaven for?"
Andrea del Sarto by Robert Browning