It took us four years from the idea of developing a regenerative burner to commercializing them

Designing any Burner is a complex process that requires careful consideration of various factors to ensure optimal performance and efficiency. With regenerative burners there is an added complication of heat exchanger design and optimization. Here are the key steps involved in designing a Regenerative burner:-


1. Initial Design Specifications

  • Define Flame Characteristics: Establish the necessary flame length, intensity, and shape based on the application requirements.

  • Set Process Parameters: Determine the appropriate air and gas pressures, as well as the desired preheat temperatures.
designing of regenerative burner

2. Heat Exchanger Design

  • Select Materials: Choose materials that can withstand high temperatures and corrosive environments.

  • Design Configuration: Develop the configuration of the heat exchangers to maximize heat transfer efficiency. This typically involves alternating between two heat exchangers to continuously recover and reuse heat.
designing of regenerative burner

3. Combustion Chamber Design

  • Size and Shape: Design the combustion chamber to accommodate the specific flame complete combustion.
  • Material Selection: Use materials that can withstand high temperatures and provide insulation to minimize heat loss.
designing of regenerative burner

4. Control System Integration

Automation and Controls: Integrate advanced control systems to manage the combustion process precisely. This includes regulating air and fuel flow, monitoring temperatures, and adjusting parameters in real-time for optimal performance.

5. Efficiency and Emission Considerations

  • Low NOx Design: Incorporate features to minimize nitrogen oxide emissions, such as staged combustion or flue gas recirculation.

  • Maximize Efficiency: Optimize the design to achieve the highest possible thermal efficiency, reducing fuel consumption and operational costs.

6. Prototype Development and Testing

  • Build Prototype: Create a prototype based on the initial design specifications.
designing of regenerative burner
Build Prototype
  • Performance Testing: Conduct rigorous testing to evaluate the burner’s performance, efficiency, and emissions. Adjust the design as necessary based on test results.

7. Optimization and Final Design

  • Refine Design: Make any necessary adjustments to optimize performance and ensure the burner meets all specifications and regulatory requirements.

  • Finalize Specifications: Document the final design specifications, including detailed drawings and operational parameters.
designing of regenerative burner

8. Field Trials

  • Site Preparation: Ensure the installation site is prepared according to the design requirements.

  • Install Burner: Install the burner and associated equipment, including heat exchangers, control systems, and fuel supply lines.

  • Commissioning: Perform commissioning tests to verify that the burner operates correctly and efficiently under actual working conditions.
designing of regenerative burner
designing of regenerative burner

9. Training and Support

  • Operator Training: Provide training for operators on the correct use and maintenance of the regenerative burner.

  • Ongoing Support: Offer ongoing technical support and maintenance services to ensure long-term performance and reliability.
designing of regenerative burner


Designing regenerative burners involves a comprehensive approach that addresses application-specific requirements, efficient heat recovery, and advanced control systems. By following these steps, ENCON Thermal Engineers Pvt Ltd ensures that each burner is tailored to deliver optimal performance, energy efficiency, and environmental compliance.

For more information or to discuss your specific needs, feel free to reach out to us.

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