Fundamentals of Process Burners 29th December 2025 – 2nd January, 2026

Course Overview

This 5-day course provides comprehensive training on process burners, covering essential topics such as burner design, installation, operation, and troubleshooting. Participants will gain a deep understanding of the combustion process in industrial settings, including the importance of burner performance in achieving optimal heat transfer and minimizing emissions. Emphasis is placed on achieving efficient combustion while ensuring safety and compliance with environmental standards. The course includes practical sessions on burner testing, flare systems, and managing pollutant emissions, ensuring a complete overview of burner fundamentals in process industries.

Course Objectives

By the end of this course, participants will be able to:

1. Understand the fundamental principles of combustion and burner operation in process industries.

2. Apply burner design concepts, including air control, air-fuel ratio, and fuel blending.

3. Troubleshoot common burner issues such as flashback, flame lift-off, and irregular flame patterns.

4. Identify the key components and design considerations for flare systems.

5. Assess and mitigate pollutant emissions from burners, with a focus on safety and environmental regulations.

Target Audience

• Process engineers and combustion specialists.

• Maintenance engineers and technicians.

• Safety officers and environmental compliance officers.

• Plant operators and managers involved in burner operations and maintenance.

• Professionals in charge of furnace and heater operations.

Daily Agenda

Day One: Introduction & Fundamentals

• Overview of burners and combustion in the process industries.

• Role of fired heaters and reformers in industrial processes.

• Competing priorities in burner design: efficiency vs. safety.

• Effects of air preheating and fuel blending on burner performance.

• Understanding stoichiometric combustion and the impact of excess air.

• Flame properties and their influence on burner efficiency.

• Heat transfer in process furnaces and its impact on burner operation.

• Burner fuels: Gaseous and liquid fuels, and their specific properties.

Day Two: Burner Design, Installation, and Testing

• Principles of burner design: air control and air-fuel ratio management.

• Types of burners: Premix, raw gas, and oil burners.

• Burner configuration considerations: Mounting types and firing direction.

• Proper burner installation techniques and alignment.

• Key aspects of burner maintenance to ensure optimal performance.

• Fundamentals of combustion control systems in burners.

• Setting up burner tests and practical applications.

• Instrumentation and measurement techniques for burner operation.

Day Three: Burner Operation & Troubleshooting

• Effective burner and heater operation techniques.

• Essential measurements: Pressure, draft, fuel flow, and fuel control.

• Operational considerations for maintaining stable combustion.

• Evaluating heater performance and its relation to burner efficiency.

• Inspection and observation techniques for identifying operational issues.

• Troubleshooting common burner issues: Flashback, flame lift-off, and irregular flame patterns.

Day Four: Flare System Design & Operation

• Introduction to flare system types and their functions.

• Objectives and applications of flare systems in process industries.

• Key components of flare systems and their role in safe operation.

• Design factors to consider when developing flare systems.

• Detailed design considerations and their impact on flare system efficiency.

• Equipment used in flare systems: Types and functionalities.

• Combustion products from flares and their environmental impact.

Day Five: Pollutant Emissions & Combustion Safety

• Nitrogen oxides (NOx) and sulfur oxides (SOx) emissions: Causes, effects, and mitigation techniques.

• Managing combustibles and particulates from burner operations.

• Carbon dioxide emissions and their environmental impact.

• Noise pollution: OSHA and international requirements for managing noise levels.

• Understanding the combustion tetrahedron and its relevance to burner operation.

• Identifying fire and explosion hazards in burner systems.

• Conducting process hazard analysis (PHA) to prevent accidents.

• Design engineering considerations: Flammability characteristics and fire extinguishment strategies.

Why Choose this Course?

This course offers a thorough understanding of process burner fundamentals, from design and installation to operation and troubleshooting. Participants will gain practical skills to improve burner performance, reduce emissions, and enhance safety in their operations. The knowledge gained will enable participants to ensure reliable burner operations and contribute to the sustainability of their facilities through reduced fuel consumption and emissions.

Learning Outcomes

By the end of this course, participants will be able to:

1. Design and configure burners for optimal combustion and efficiency.

2. Troubleshoot common burner issues and apply corrective actions.

3. Understand and implement flare system design principles.

4. Evaluate and manage pollutant emissions from burners to comply with environmental regulations.

5. Apply safety measures to prevent fire and explosion hazards in burner operations.