Ultra High Efficiency Furnaces

3-Crucible Zinc Vaporizer

Zinc vaporizing furnace designed by industrial furnace specialists with the cooperation of experts from the zinc oxide industry.

Ultra High Efficiency

Our 3-crucible zinc vaporizing furnace utilizes a regenerative burner technology to produce ZnO at less than 3.2 GJ/tonne. This efficiency is up to 500% greater than other zinc vaporizers currently operating globally. At the lowest estimate, this furnace can save up to $150,000/year in fuel alone.  Additional savings come from higher then typical Zn to ZnO conversion rate and lower metal losses.

Optimized Design

Engineered using the latest in CFD (Computational Fluid Dynamics) technology, our designs have been extensively fine-tuned against real world operating data to optimize the furnace chamber shape and burner configuration.

The result is the most efficient crucible furnace available to the zinc oxide producer. 


Furnace type: 3-ceramic crucibles
Crucible life: 3-4 months

Production rate = 20 t/day ZnO
Production efficiency < 3.2 GJ/t ZnO
Zn to ZnO conversion rate > 1.225
Preferred Zinc Source: SHG
Good Source : Low Pb Secondary
Burners = 1200 kW regenerative
Emissions: Ultra low NOx, Low CO2

2-Retort Zinc Vaporizer

Designed for producing ZnO from secondary zinc. This high efficiency furnace can easily handle Pb and other contaminants.

Ultra High Efficiency

Like our 3-crucible vaporizer, this 2-retort furnace utilizes a unique chamber shape and regenerative burner technology to produce ZnO at approximately 3.5 GJ/t. 

In addition to the quick drain feature, the furnace uses automated refill procedure to minimize thermal shock to the retorts. 

Optimized Design

Designed by industrial furnace experts using CFD technology. Evolving designs have been extensively fine-tuned against real world results, to produced a furnace design with optimized shape, retort layout, and burner configuration. The result is the most efficient furnace with excellent zinc temperature uniformity.


Furnace type: 2-retort horizontal
Retort life: 3-4 months

Production rate = 12 t/day ZnO
Production efficiency < 3.5 GJ/t ZnO
Zn to ZnO conversion rate > 1.215
Preferred Source: SHG or Secondary
Burners = 900 kW regenerative
Emissions: Ultra low NOx, Low CO2  

Swing Zinc Processing Furnace

Designed to remove Iron from Secondary Zinc

Innovative Design

The shape and operation of this innovative melting furnace have been specifically designed to separate contaminants from secondary zinc. Contents of the furnace are mixed with a reagent metal to produce reactions which separate the contaminant metals from the zinc. The process achieves almost complete removal of all contaminants except for Cd and Pb. The swing feature allows for controlled tip-out of clean zinc or clean-out of contaminants.

Dual Purpose

Designed to pre-melt SHG zinc and to dissolve hard Secondary Zinc. The process extracts iron and most other contaminants from the bath, enabling the production of white grade zinc oxide from secondary zinc sources.

Forward tilt allows controlled tip-out of clean zinc and gravity transfer to the vaporizing furnace. Rear tilt helps the operator to clean out ash and the separated contaminants.


Furnace type: Swing Zinc Melter
Available Sizes = 24t/d, 48t/d, 72t/d
Melting efficiency < 0.7 GJ/t Zn
Ideal application: SHG or hard zinc 

Process produces typically 99.9% pure Zn (with low Pb feed material) .

For locations where deep foundations are needed for gravity feed but are not possible, this furnace is available as a static furnace discharged by pump.

Zinc Melting/Processing Furnace

A static version of the Swing Processing Furnace may be used in situations where construction of a deep foundation for gravity discharge is not feasible. 

Pump Discharge Option

This static furnace has an extended side well to accommodate a discharge pump, an agitator, and a second auxiliary pump. The same mixing flow is generated as in the swing furnace to ensure the same operational efficiency. In the event that SGH or HG zinc is to be processed exclusively, a low volume variant of the this static furnace may be the best option for you.


• Thermally efficient design
• Excellent temperature uniformity
• Pump discharge system
• Optional zinc flow meter
• Extended pre-heating dry shelf 
• Full width loading/cleaning access
• Front loading by forklift truck
• Top loading by overhead crane
• Left/Right side discharge option


• Furnace Type: Static Zinc Melter
• Capacity = 25 tonnes
• Operating T= 465C to 475C
• Production Rate = up to 50 t/day
• Zinc Storage for 20,000 t/y plant
• Melting efficiency = 0.7 GJ/t Zn
• Holding efficiency = 0.3 GJ/t Zn
• Material: SHG or processed zinc
• Burners = 580 kW High Velocity

Automated Launder & Tundish

Auxiliary equipment designed to simplify the process of transferring liquid zinc from the melters to the vaporizers

Remote Controlled Launder

Allows the operator to quickly and conveniently transfer liquid zinc from the melting or swing furnace to the vaporizing furnace. The operator has complete control of the launder movement using a wearable control box, or a fork-lift mounted panel.

The launder tip is designed to pour zinc into the vaporizing furnace from the side of the zinc flame, avoiding disruption of the flame during the transfer.  


Full launder automation packages are available for the 2-retort and 3-crucible furnaces for fully autonomous operation.

When used in conjunction with the metal flow meter, the operator can program the system to transfer exact quantities of liquid zinc to the retort or crucible.

A tundish is required for zinc transfer from a swing furnace.


Swing  Angle =  270 deg.
Swing Radius  =  7.2 m
Transfer Rate  =  250 kg/m
Static Zinc Capacity  =  600 kg            

Launder tip = Reaction Bonded SiC
Preheat stations available
Flow meter option available

Auto Position Control +/- 2mm
Auto Level Control +/-  5mm

Zinc Precipitate Squeezer

Stand-alone equipment designed to extract metallic zinc from the Swing Zinc Processing furnace skimmings.


Designed to recover remaining zinc from the Processing Furnace skimmings after separating the contaminant metals. Achieves better than 85% metal zinc recovery when the ashes are oxidized.


Sized to handle skimmings from the swing zinc processing furnace when processing secondary feed material containing nominally 2% Iron.  A mobile version of the squeezer is available. 


Capacity =  260 L
Precipitate capacity = 500 kg
Best extraction efficiency = 90%*
Motor = 7.5 kW / Heaters = 36 kW

* Based on quantity of free zinc


A. H. Burns Energy Systems Ltd.
1-1370 Sandhill Drive,
Ancaster, ON, Canada  L9G 4V5


Email: info@burnsenergy.ca           Phone:  905.525.6321