Case Study: Burner Optimization In St. Louis: Modernizing A 1980s Metal Finishing Furnace System

Industrial Furnace Retrofit for Increased Efficiency and Safety

One long-standing copper products manufacturer was grappling with aging furnace infrastructure from the 1980s. Diminishing performance, hard-to-source replacement parts, and an outdated burner system were causing significant downtime and reliability issues. As a trusted combustion partner since the ’80s, we delivered a turnkey upgrade that replaced their obsolete pre-mix burners with modern nozzle-mix burners and state-of-the-art controls. The result: increased uptime, reduced maintenance, and a safer, more efficient furnace operation.

About the Client: A Legacy Copper Manufacturer with Mission-Critical Heating Systems

The manufacturer produces copper tubes and products for a variety of industrial applications. Known for their solid metal billets and precise manufacturing standards, their processes rely heavily on furnace performance and uptime. We’ve been a partner since the 1980s, providing service, parts, and engineering expertise.

The Challenge: Outdated Burner Systems Disrupting Production

The project focused on one aging furnace system that had reached the end of its serviceable life. Originally designed with a pre-mixed burner system, the furnace presented numerous challenges:

Outdated Technology: The pre-mix burners were 15-20 years past obsolescence, with no available parts or support.
Aging Infrastructure: Gas and air piping was rusted and corroded, some of it affected by internal water damage.
Legacy Controls: The control panel was packed with outdated amplifiers and modules that had long been discontinued.
Slow Startup and Frequent Downtime: Pilot ignition systems were inefficient and unreliable.
Zone-Wide Burner Shutdowns: The furnace was divided into three zones, each with eight burners. If a single burner lost flame signal, the entire zone had to shut down—a situation referred to as “one-down, all-out.” This design caused significant temperature loss while operators worked to re-light all eight burners in the affected zone.

Compounding the issue was the system’s complexity and the pressure to maintain production despite equipment issues. The manufacturer had long known a retrofit was necessary, but capital expenditure and system familiarity delayed action for several years.

The Solution: Comprehensive Burner Optimization and Control System Upgrade

We engineered a full system retrofit to bring the furnace into the 21st century. The new system replaced the outdated pre-mixed burners with 24 nozzle-mix burners, mounted across both sides of the 50-foot-long furnace.

Key upgrades included:

Burner Replacement: Nozzle-mix burners with direct spark ignition eliminated the need for pilots, reducing maintenance and improving reliability.
Control Panel Replacement: A new, dual-cabinet panel separated high-voltage and low-voltage functions and incorporated modern flame safety and motor control logic.
Mechanical Install: BDC coordinated the removal of the old system and the welding and mounting of new burners. Gas and air piping were replaced and re-routed to meet updated specs.
Three-Zone Control: The system was zoned for optimized temperature control, supporting the furnace’s 1700-1800°F operation range.
Improved Flame Safety Design: We upgraded the system to a “one-down, one-out” configuration. Now, if a burner loses flame signal, only that individual burner shuts down—allowing the remaining burners in the zone to continue operation. This change significantly reduced temperature swings and improved overall system stability.

Implementation Process: Safe Execution with Minimized Downtime

Our team of engineers collaborated with the manufacturer’s internal team to execute the upgrade. Work included:

Demolition of the obsolete burner hardware
Custom welding of adapter plates for new burners
Gas and air header replacement for 24 burner connections
Field wiring reconnection from legacy conduits to the new panel
Full system commissioning and ignition testing

Results: Immediate Gains in Reliability and Compliance

The retrofit delivered immediate and measurable improvements:

Reduced Downtime: Elimination of hard-to-source parts and outdated controls significantly decreased unplanned outages.
Faster Heat-Up: The new burners improved responsiveness, cutting startup time.
Simplified Maintenance: Direct spark ignition and modern flame scanners made the system easier to troubleshoot.
Safety Compliance: Updated flame safety devices and zone temperature controls met modern NFPA86 standards.
Operational Efficiency: The shift to “one-down, one-out” control minimized process interruptions, supporting more stable furnace operation and better product consistency.

Why BDC: St. Louis-Based Experts in Burner Optimization and Control Systems

The manufacturer chose our team because of its niche expertise, decades-long relationship, and proven ability to translate combustion challenges into safe, effective engineered systems. BDC focuses solely on industrial combustion, bringing unmatched technical depth to every project. For burner optimization in St. Louis and beyond, our team of experts deliver specialized insight that drives performance.

Trusted Retrofit Partner for Industrial Furnace Challenges

By retrofitting this 1980s furnace, we didn’t just replace obsolete hardware—we restored reliability, improved safety, and reestablished a foundation for long-term production performance. For manufacturers facing aging infrastructure and combustion system challenges, it’s important to consider how not doing equipment upgrades could cost you in the short term and long term.

Whether you have aging equipment or not, our team of burner experts is here to help optimize your system for maximum performance.