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Custom Burner Systems Engineered for Australian Process Industries
Ever-power designs and manufactures custom burner systems tailored to the exact thermal load, fuel mix and emissions envelope of each plant. Power ratings cover 30 kW for compact heat treatment up to 12,000 kW for large refinery and petrochemical duty, with multi-fuel capability across natural gas, LPG, fuel oil, refinery off-gas and specialised industrial fuels. Every burner package is built from validated CFD models, hardware tested at our combustion lab, and shipped with full documentation aligned to AS/NZS 3814 and AGA approval pathways.
What Makes a Custom Burner the Right Choice
Off-the-shelf burners often force operators to compromise on flame length, heat distribution or fuel flexibility. A custom burner system removes those compromises. Our engineering team starts with your process drawing, fuel analysis and emissions target, then sizes the throat, register, atomiser and igniter set as a matched assembly. The result is a burner that drops into existing refractory openings, holds turndown across the operating envelope and meets jurisdictional NOx limits without bolt-on abatement.
Custom Burner System Specifications
| Parameter | Standard Range | Custom Option |
|---|---|---|
| Thermal Capacity | 30 to 12,000 kW | Up to 25 MW on multi-burner blocks |
| Turndown Ratio | 10:1 | Up to 20:1 with modulating control |
| NOx Emissions (gas) | ≤ 80 mg/Nm3 | ≤ 30 mg/Nm3 with internal staging |
| CO Emissions | ≤ 50 mg/Nm3 | ≤ 20 mg/Nm3 |
| Operating Pressure | 2 to 50 kPa | Up to 0.6 MPa for high-pressure duty |
| Air Preheat Tolerance | Ambient to 300 °C | Up to 550 °C with high-temp register |
| Ignition | Direct spark, gas pilot | Continuous interrupted pilot, UV scan |
| Flame Detection | UV or ionisation | Self-checking dual UV with BMS |
| Approvals | CE, ISO 9001 | AS/NZS 3814, AGA, FM, ATEX |
Burner Configurations We Engineer
For fired heaters, reformers and cracking furnaces in refining and petrochemicals.
Watertube and firetube duty up to 80 t/h steam generation.
Inline supplementary firing for HRSG and cogeneration trains.
High-turndown burners for thermal oxidisers, RTOs and waste destruction units.
Reliable ignition and stable pilots for emergency relief flares.
Cement, lime, alumina and mineral processing duty with multi-fuel handling.
Engineering Workflow from Enquiry to Commissioning
| Stage | Deliverable | Typical Lead Time |
|---|---|---|
| Process review and fuel analysis | Heat balance, datasheet | 5 to 10 days |
| CFD modelling and flame shaping | Flame envelope, NOx prediction | 2 to 3 weeks |
| Mechanical design and approval | GA drawings, BOM, P&ID | 2 weeks |
| Fabrication and FAT | Witness firing report | 8 to 14 weeks |
| Site commissioning | Tuning, emissions verification | 3 to 7 days on site |
Why Australian Operators Choose Ever-power
For an introduction to our broader thermal-treatment portfolio, visit our company homepage and explore the full range of oxidiser and combustion technology.
Australian Project Highlight
A specialty chemicals manufacturer near Geelong needed to retrofit an ageing fired heater that could no longer meet the EPA Victoria NOx licence limit of 100 mg/Nm3. Ever-power supplied a custom 4,200 kW process burner with internal staging and dual-fuel handling for natural gas and refinery off-gas.
Frequently Asked Questions
How long does it take to engineer a custom burner system?
From a complete enquiry pack we deliver a firm proposal within 10 working days. Detailed engineering, fabrication and FAT typically run 14 to 18 weeks for power ratings up to 12,000 kW. Larger multi-burner blocks may extend to 22 weeks.
Can a custom burner be retrofitted into an existing furnace opening?
Yes. We design the burner block and mounting flange to match your existing refractory throat and tile. Site survey drawings, photographs and a thermal scan of the firebox are usually enough to confirm a drop-in fit.
What NOx levels are achievable on natural gas?
Standard low-NOx designs achieve 60 to 80 mg/Nm3 at 3% O2 reference. Internal staging brings figures to 30 to 40 mg/Nm3. With external flue gas recirculation, single-digit NOx in the 20 mg/Nm3 range is achievable.
Do you support dual-fuel and tri-fuel arrangements?
Yes. Common pairings include natural gas with diesel back-up, natural gas with refinery off-gas, and natural gas with biogas. Switchover can be hot or cold, automatic or manual, depending on plant philosophy.
Are your custom burner systems certified for the Australian market?
All packages can be supplied with AS/NZS 3814 compliant gas trains and AGA-listed components. Burner management systems are built to AS 3814 and IEC 61508 SIL2 where required.
What spare parts should we hold on site?
A recommended spares list is supplied with every order. Critical items include the gas tip set, oil atomiser cap, ignition electrode, UV flame scanner and igniter transformer. Most plants stock one full set per burner.
Do you provide commissioning support in Australia?
Yes. We dispatch a combustion specialist for site supervision, light-off, tuning and emissions verification. Remote support is also available via secure VPN to the burner management system.
Talk to a Combustion Specialist
Send your fuel analysis, furnace drawings and emissions target. You will receive a written technical response within five working days, including indicative heat release, flame envelope and budget pricing.
