{"id":1256,"date":"2026-04-28T07:09:52","date_gmt":"2026-04-28T07:09:52","guid":{"rendered":"https:\/\/rtooxidizer.com\/?post_type=product&p=1256"},"modified":"2026-04-28T07:09:53","modified_gmt":"2026-04-28T07:09:53","slug":"custom-burner-systems","status":"publish","type":"product","link":"https:\/\/rtooxidizer.com\/nl\/product\/custom-burner-systems\/","title":{"rendered":"Custom Burner Systems"},"content":{"rendered":"
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Custom Burner Systems Engineered for Australian Process Industries<\/h2>\n

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.<\/p>\n

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\"Ever-power<\/div>\n
\"Custom<\/div>\n<\/div>\n

What Makes a Custom Burner the Right Choice<\/h2>\n

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.<\/p>\n

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Tailored Flame Geometry<\/div>\n
Short bushy flames for shell boilers, long pencil flames for tubular reformers, or flat radiant fields for cracking furnaces.<\/div>\n<\/div>\n
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30 kW to 12,000 kW<\/div>\n
Full coverage from laboratory pilot units up to large utility boilers, with turndown ratios of 10:1 typical and 20:1 available.<\/div>\n<\/div>\n
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Low-NOx by Design<\/div>\n
Internal staging and lean premix architectures deliver NOx down to 30 mg\/Nm3 without flue gas recirculation, lower with FGR.<\/div>\n<\/div>\n
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Multi-Fuel Capable<\/div>\n
Natural gas, LPG, propane, diesel, heavy fuel oil, biogas and process off-gas, including dual-fuel and tri-fuel arrangements.<\/div>\n<\/div>\n<\/div>\n

Custom Burner System Specifications<\/h2>\n
\n\n\n\n\n\n\n\n\n\n\n\n\n\n
Parameter<\/th>\nStandard Range<\/th>\nCustom Option<\/th>\n<\/tr>\n<\/thead>\n
Thermal Capacity<\/td>\n30 to 12,000 kW<\/td>\nUp to 25 MW on multi-burner blocks<\/td>\n<\/tr>\n
Turndown Ratio<\/td>\n10:1<\/td>\nUp to 20:1 with modulating control<\/td>\n<\/tr>\n
NOx Emissions (gas)<\/td>\n\u2264 80 mg\/Nm3<\/td>\n\u2264 30 mg\/Nm3 with internal staging<\/td>\n<\/tr>\n
CO Emissions<\/td>\n\u2264 50 mg\/Nm3<\/td>\n\u2264 20 mg\/Nm3<\/td>\n<\/tr>\n
Operating Pressure<\/td>\n2 to 50 kPa<\/td>\nUp to 0.6 MPa for high-pressure duty<\/td>\n<\/tr>\n
Air Preheat Tolerance<\/td>\nAmbient to 300 \u00b0C<\/td>\nUp to 550 \u00b0C with high-temp register<\/td>\n<\/tr>\n
Ignition<\/td>\nDirect spark, gas pilot<\/td>\nContinuous interrupted pilot, UV scan<\/td>\n<\/tr>\n
Flame Detection<\/td>\nUV or ionisation<\/td>\nSelf-checking dual UV with BMS<\/td>\n<\/tr>\n
Approvals<\/td>\nCE, ISO 9001<\/td>\nAS\/NZS 3814, AGA, FM, ATEX<\/td>\n<\/tr>\n<\/tbody>\n<\/table>\n<\/div>\n

Burner Configurations We Engineer<\/h2>\n
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\nProcess Burners<\/strong><\/div>\n

For fired heaters, reformers and cracking furnaces in refining and petrochemicals.<\/span><\/p>\n<\/div>\n

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\nPackage Boiler Burners<\/strong><\/div>\n

Watertube and firetube duty up to 80 t\/h steam generation.<\/span><\/p>\n<\/div>\n

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\nDuct Burners<\/strong><\/div>\n

Inline supplementary firing for HRSG and cogeneration trains.<\/span><\/p>\n<\/div>\n

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\nIncinerator and RTO Burners<\/strong><\/div>\n

High-turndown burners for thermal oxidisers, RTOs and waste destruction units.<\/span><\/p>\n<\/div>\n

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\nFlare and Pilot Systems<\/strong><\/div>\n

Reliable ignition and stable pilots for emergency relief flares.<\/span><\/p>\n<\/div>\n

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\nKiln and Calciner Burners<\/strong><\/div>\n

Cement, lime, alumina and mineral processing duty with multi-fuel handling.<\/span><\/p>\n<\/div>\n<\/div>\n

\"Engineered<\/div>\n

Engineering Workflow from Enquiry to Commissioning<\/h2>\n
\n\n\n\n\n\n\n\n\n\n
Stage<\/th>\nDeliverable<\/th>\nTypical Lead Time<\/th>\n<\/tr>\n<\/thead>\n
Process review and fuel analysis<\/td>\nHeat balance, datasheet<\/td>\n5 to 10 days<\/td>\n<\/tr>\n
CFD modelling and flame shaping<\/td>\nFlame envelope, NOx prediction<\/td>\n2 to 3 weeks<\/td>\n<\/tr>\n
Mechanical design and approval<\/td>\nGA drawings, BOM, P&ID<\/td>\n2 weeks<\/td>\n<\/tr>\n
Fabrication and FAT<\/td>\nWitness firing report<\/td>\n8 to 14 weeks<\/td>\n<\/tr>\n
Site commissioning<\/td>\nTuning, emissions verification<\/td>\n3 to 7 days on site<\/td>\n<\/tr>\n<\/tbody>\n<\/table>\n<\/div>\n

Why Australian Operators Choose Ever-power<\/h2>\n
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Two Decades of Combustion Engineering<\/div>\n
More than 4,000 burner installations commissioned across petrochemicals, refining, food, paper and minerals processing.<\/div>\n<\/div>\n
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In-house CFD and Hot Lab<\/div>\n
Validated combustion models and a dedicated test rig let us de-risk every flame profile before fabrication.<\/div>\n<\/div>\n
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Local Compliance Knowledge<\/div>\n
EPA Victoria, EPA NSW, DWER WA and Queensland licence conditions are addressed at the design stage.<\/div>\n<\/div>\n
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Lifetime Spare Parts Support<\/div>\n
Burner tips, atomisers, igniters and flame scanners stocked for legacy and current series.<\/div>\n<\/div>\n<\/div>\n

For an introduction to our broader thermal-treatment portfolio, visit our company homepage<\/a> and explore the full range of oxidiser and combustion technology.<\/p>\n

Australian Project Highlight<\/h2>\n
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Geelong Specialty Chemicals Plant, Victoria<\/div>\n

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.<\/p>\n

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NOx Reduction<\/div>\n
62%<\/div>\n<\/div>\n
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Fuel Saving<\/div>\n
7.4%<\/div>\n<\/div>\n
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Commissioning<\/div>\n
5 days<\/div>\n<\/div>\n
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Uptime since<\/div>\n
99.6%<\/div>\n<\/div>\n<\/div>\n<\/div>\n

Frequently Asked Questions<\/h2>\n
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\nHow long does it take to engineer a custom burner system?<\/summary>\n

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.<\/p>\n<\/details>\n

\nCan a custom burner be retrofitted into an existing furnace opening?<\/summary>\n

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.<\/p>\n<\/details>\n

\nWhat NOx levels are achievable on natural gas?<\/summary>\n

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.<\/p>\n<\/details>\n

\nDo you support dual-fuel and tri-fuel arrangements?<\/summary>\n

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.<\/p>\n<\/details>\n

\nAre your custom burner systems certified for the Australian market?<\/summary>\n

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.<\/p>\n<\/details>\n

\nWhat spare parts should we hold on site?<\/summary>\n

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.<\/p>\n<\/details>\n

\nDo you provide commissioning support in Australia?<\/summary>\n

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.<\/p>\n<\/details>\n<\/div>\n

Talk to a Combustion Specialist<\/h2>\n
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Ready to specify your custom burner system?<\/div>\n

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.<\/p>\n

Email sales@rtooxidizer.com<\/a>
\nSubmit RFQ<\/a><\/div>\n<\/div>\n