Furnace Design & Fabrication Detailing Services | Complete Combustion

Complete Combustion offers comprehensive furnace, oven, and heater design services, including thermal process engineering, mechanical design, heat balance, and fabrication detailing. Our team provides P.Eng-stamped drawing packages for all industrial heating equipment across the USA and Canada. As an independent design practice operating under a Professional Engineers Ontario (PEO) Certificate of Authorization, we deliver optimized, vendor-neutral heating system designs tailored to your process requirements and code-compliance mandates.

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End-to-End Thermal & Mechanical Engineering Capabilities

Every industrial heating application presents unique thermodynamic and mechanical challenges. Complete Combustion engineers each system from foundational heat-transfer calculations through to fabrication-ready CAD drawings and regulatory submittal packages.

1. Thermal Process Modeling & Heat Balances

Accurate thermal calculations are essential to prevent oversized equipment, excessive fuel consumption, or insufficient process heating. We perform detailed mathematical modeling to determine:

• Gross & Net Firing Heat Input: Sizing total heat release (MMBtu/hr or MW) based on material throughput, moisture content, and target operating temperatures.
• Sensible & Latent Heat Calculations: Evaluating enthalpy changes in work materials, evaporation rates, and enclosure heat storage.
• Combustion Stoichiometry: Determining precise air-to-fuel ratios across variable excess air conditions to achieve target flame temperatures and minimize emissions.
• PURGE Timing Verification: Calculating equipment volume displacement and required air pre-purge durations compliant with CSA B149.3/NFPA 86.
• Pressure Drop Calculations: Modeling fuel and air piping systems for optimal flow and minimal pressure loss.
• Burner/Regulator/Valve Sizing and Selection: Evaluating required flow and pressure drops to ensure proper combustion control.

2. Structural & Fabrication Detailing

Our mechanical design team develops fabrication-ready drawings and specifications for industrial furnaces, ovens, and heaters:

• Refractory & Insulation Design: Thermal analysis and material selection per ASTM C680 standards.
• Structural Enclosure Design: CAD modeling for shell, frame, and support structures ensuring compliance with ASME and CSA codes.
• Burner Mounting & Integration: Layouts for burner placement, flame monitoring, and safety interlocks.
• Access & Maintenance Provisions: Ergonomic design for inspection ports, doors, and service access.

3. Performance Optimization & Compliance

We ensure all designs meet stringent performance and safety standards:

• Energy Efficiency Optimization: Minimizing heat losses through advanced insulation and heat recovery systems.
• Emission Control Integration: Incorporating low-NOx burner technologies and exhaust treatment systems.
• Code Compliance: Designs conform to CSA B149.3, NFPA 86, and AISC-CISC standards.