Combustion & Electrical Systems for Industrial Dryers & Kilns

Complete Combustion provides licensed, P.Eng-stamped combustion system design, burner integration, and centralized electrical modernization engineering for industrial drying and calcining operations across Ontario and Canada. Operating under a PEO Certificate of Authorization, we engineer integrated thermal, mechanical, and electrical solutions for continuous rotary drum dryers, batch aggregate dryers, mineral processing kilns, and asphalt mixing plants.

Core Engineering Capabilities

1. Burner Mounting, Tile Weldments & Thermal Integration

• Custom Burner Selection & Mounting: Engineering mounting arrangements for high-capacity packaged burners firing natural gas, propane, or fuel oil.
• Burner Tile Weldments & Refractory Castings: Designing heavy-duty structural burner support frames, burner tile weldments, and cast refractory nose rings engineered to withstand high radiant temperatures and thermal cycling.
• Combustion Air & Transition Ducting: Sizing forced draft blowers, intake filtration hoods, and transition ductwork to deliver stable excess air across fluctuating material feed rates.

2. Centralized Motor Control Panel (MCP) Engineering

• Unified Power Distribution: Combining motor starters, VFDs, and branch circuit protection for hoppers, conveyors, rotary drum drives, combustion blowers, and packaging lines into one centralized NEMA-rated enclosure.
• Coordinated Overload & Feeder Protection: Precise sizing of motor protection circuit breakers, contactors, and thermal overloads matched to continuous FLA and service factors.
• Step-Down Transformer Engineering: Sizing dry-type transformers (480V or 600V to 120/208V) to power plant utilities directly from the main generator, eliminating secondary generator costs.

3. Integrated Plant Safety Circuits & Conveyor Pull-Wire E-Stops

• CSA & ESA Compliant Safety Logic: Engineering safety-rated control relays that integrate emergency stop pushbuttons and bi-directional pull-wire switches along all conveyor spans into a unified safety loop.
• Fail-Safe Fuel Interlocks: Direct hardware interlocking between burner flame safeguard controls, drum rotation sensors, and exhaust airflow switches to prevent fuel delivery if drum rotation stalls or draft fails.

4. Thermal Sizing & Purge Calculations

• Moisture Evaporation Modeling: Heat balance calculations to determine the gross firing rate required to achieve target discharge moisture content.
• NFPA 86 Volumetric Purge Sizing: Mathematical calculation of dryer drum volume and baghouse ducts to establish mandatory fresh-air purge timing prior to burner ignition.

Supported Industrial Drying Equipment

• Rotary Drum Batch Dryers: Direct-fired rotary dryers for stone, gravel, sand, and aggregate drying.
• Continuous Mineral Processing Kilns: Counter-flow and parallel-flow rotary kilns for lime, gypsum, and mineral calcining.
• Asphalt Plant Dryers: High-capacity aggregate drying drums for continuous and batch-mix asphalt manufacturing plants.

Frequently Asked Questions

How does consolidating motor starters into a centralized MCP reduce plant downtime?
In fragmented plants, diagnosing a tripped motor or interlock fault requires technicians to walk between scattered disconnects and individual starter boxes. A centralized MCP places all breakers, overload relays, and safety relays in one location, allowing maintenance personnel to identify and reset faults in minutes rather than hours.

What calculations are required for TSSA approval on a rotary dryer burner retrofit?
A TSSA submission under CSA B149.3 requires stamped P&IDs, valve train pressure drop calculations, valve sizing schedules, electrical flame safeguard schematics, a Sequence of Operations, and NFPA 86 volumetric pre-purge calculations based on total drum and ductwork cubic footage.

Consult with Our Team

• Office: 33 Paddington Rd, Brampton, ON L6P 2E3
• Phone: +1 647 554 8108
• Email: info@completecombustion.ca

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