Process Combustion Systems

Name

Process Combustion Systems

Legal name

Process Combustion Systems Inc.

Website

https://processcombustion.com

Company type

Private

Founded year

1981

Operating status

Acquired

Headcount range

11–50 employees

Short description

Process Combustion Systems Inc. is a Calgary-based custom-engineered industrial combustion systems integrator, designing and servicing ultra-low NOx burners, burner management systems, and heating equipment for mining, oil & energy, steel, and other heavy industrial clients across North America.

Ownership category

akta.pro rank

Product category

Industrial Combustion and Process Heating Equipment

NAICS

Industrial Process Furnace and Oven Manufacturing (333994), Heating Equipment (except Warm Air Furnaces) Manufacturing (333414), Power Boiler and Heat Exchanger Manufacturing (332410)

SIC

Industrial Process Furnaces & Ovens (3567), Heating Equipment, Except Electric & Warm Air Furnaces (3433), Air-Cond & Warm Air Heatg Equip & Comm & Indl Refrig Equip (3585)

akta.pro primary industry

Boilers, Furnaces & Process Heating Equipment (IMAHAKAD)

akta.pro secondary industry

Heat Transfer Equipment (Heat Exchangers, Boilers, Condensers) (IMAHAEAC)

Keywords

• Industrial combustion systems
• Burner management systems
• Low NOx burners
• Mine air heating
• Process heating equipment

Headquarters

HQ city

Calgary

HQ country

Canada

HQ region

North America

Offices2 records

Markets served

GTM type

B2B

Offering type

Hardware or Manufacturing

Cost components

Personnel, Supply Chain, Operations, Technology or R&D, Marketing or Sales, Infrastructure

Revenue model

1. Custom Engineered Equipment Sales: Design, engineering, fabrication, and supply of custom burner systems, boiler burners, retrofits, OTSG burners, mine air heaters, rotary/fluid bed dryers, heat treating ovens, ladle preheaters, startup/preheating systems, and custom furnaces. Turn-key packages delivered to industrial customers.
2. Parts and Aftermarket Equipment: Sale of factory-tested parts and equipment including flame safeguard and safety systems, flame scanners, high energy spark igniters, gas regulators, blowers, waste heat recovery systems, safety shutoff valves, custom airflow metering, digital temperature controllers, and control valves.
3. Field Services: Recurring and project-based professional services including commissioning & start-up, flame safeguard troubleshooting, system run-up / combustion analysis / process tuning, and preventive maintenance on critical process furnaces and burner controls.
4. Rental Boiler Solutions: Rental of trailer-mounted and skid-mounted boilers (30,000–125,000 PPH saturated steam, 60,000–110,000 PPH superheated steam, 200,000 PPH skid-mounted superheated, 48–1500 HP firetube) along with auxiliary equipment (SCR units, economizers, ammonia-free SCR) for temporary/emergency steam requirements.
5. Burner Management and Combustion Control Integration: Design, integration, and supply of PLC-based burner management systems, combustion controls, and flame safeguard solutions, often bundled with turn-key equipment packages.

Go-to-market motion3 records

Distribution channels5 records

Marketing channels6 records

Core offering

Process Combustion Systems Inc. (PCSI) designs, engineers, builds, tests, and services custom industrial combustion and heating systems for large industrial customers. Its product portfolio includes burner management systems, boiler burners and retrofits, OTSG burners, rotary and fluid bed dryers, mine air heating and ventilation systems, heat treating ovens and ladle preheaters, startup/preheating hot gas generators, custom furnaces, and a rental boiler fleet, complemented by a parts/aftermarket catalog (flame safeguard, flame scanners, igniters, gas regulators, blowers, waste heat recovery, safety valves, airflow metering, temperature controllers, and control valves).

Product overview

Process Combustion Systems Inc. (PCSI) is a custom-engineered industrial combustion platform organized around a core portfolio of integrated systems and a comprehensive parts/components catalog, rather than a single unified software product. At the platform level, PCSI designs, builds, services and tests turn-key Burner Management Systems & Combustion Control Upgrades, Boiler Burners and Retrofits, Once-Through Steam Generator Burners, Rotary & Fluid Bed Dryers, Mine Air Heating & Ventilation systems, Heat Treating Ovens & Ladle Preheaters, Startup/Preheating Hot Gas Generators, and Custom Furnaces & Solutions, complemented by a Rental Boiler Solutions service. Supporting these systems is an extensive parts catalog (Flame Safeguard and Safety Systems, Flame Scanners, High Energy Spark Igniters, Gas Regulators, Industrial Blowers, Waste Heat Recovery / HRSG, CSA Approved Safety Shut-Off and Isolation Valves, Custom Air Flow Metering Systems, Digital Temperature Controllers, and Control Valves and Ratio Regulators) drawing on technology partners such as Fireye, E-Tech, Fives (Fives Pillard) and Victory Energy. All custom PCSI part assemblies are factory tested prior to shipment and PCSI also operates a new in-house test facility for functional, fuel-flexibility, emissions and controls/diagnostics testing. The portfolio is held together by shared field services — commissioning/start-up, flame-safeguard troubleshooting, combustion analysis/tuning and preventative maintenance — and is now integrated within the DCM Group.

Differentiator

Problem solved

Functional benefit

Brands

• PCSI: Short-form commercial brand used by Process Combustion Systems Inc. for its industrial combustion, burner, and heating system products and services.

Products and services

• Burner Management Systems & Combustion Control Upgrades PLC-based Burner Management Systems and combustion control upgrades designed to meet CSA and NFPA standards, applicable to both complex new burner installations and legacy equipment upgrades.
• Boiler Burners and Retrofits Custom-engineered burner selection and combustion controls for large industrial boilers and HRSGs, designed to maximize boiler longevity, reliability and operation in both new and retrofit applications.
• Once-Through Steam Generator (OTSG) Burners Ultra-low-NOx burner systems for Once-Through Steam Generators used in steam flood and enhanced heavy-oil recovery, designed to meet corporate and federal emissions standards.
• Rotary Dryers & Fluid Bed Dryers Combustion systems for mineral processing rotary and fluid bed dryers delivering even heat flux, uniform temperatures and low emissions; PCSI was one of the first to implement ultra-low-NOx dryer systems in North America.
• Mine Air Heating & Ventilation Systems Air heating and mine ventilation solutions for the mining industry, including direct-fired Ultra Low NOx, conventional natural gas/propane, indirect diesel-fired, glycol, and electric/hybrid systems. PCSI is the largest mine air heater supplier in Canada.
• Heat Treating Ovens & Ladle Preheaters Custom-built ovens for heat treating and coating applications, including large multi-burner/multi-zone systems for pipe coating, plus high-temperature and high-velocity burners for ladle preheaters.
• Rental Boiler Solutions Rental boiler and auxiliary equipment for temporary/emergency steam requirements, including 30,000-125,000 PPH saturated and 60,000-110,000 PPH superheated trailer-mounted boilers, 200,000 PPH skid-mounted superheated boilers, and 48-1500 HP skid-mounted firetube boilers, with backend SCR / economizer / ammonia-free SCR cleanup and CSA/CRN approval support.
• Startup and Preheating Systems (Hot Gas Generators) Hot gas generators built to deliver uniform outlet-chamber temperatures and to handle frequent thermal cycling, providing complete solutions for acid-plant startup and preheat applications.
• Custom Furnaces & Solutions Fully custom combustion and furnace systems engineered to customer requirements, supporting a wide range of fuels and control schemes.
• Flame Safeguard and Safety Systems Flame safeguard and burner management product line including Burner Logix YB110/YB230, Fireye Micro M, Fireye E100 Flame Monitor series, Honeywell 7800L, and BLV512, providing continuous flame monitoring, auto-diagnostics, and safe burner shut-down.
• Flame Scanners UV, IR and dual-sensor flame scanners (45UV5, 55UV5, 65UV5, InSight 95IR/95UV/95DS, UV1A, 48PT2) for fossil-fuel flame detection, suitable for hazardous-location industrial burners.
• High Energy Spark Igniters Direct-spark ignition solutions including Frederick Cowan Complete Ignition Kits, Chentronics Gas Turbine Igniters, and PCSI High-Energy Spark Ignitor Assemblies for industrial burners and gas turbines in extreme conditions.
• Gas Regulators Industrial gas regulators from Norgas, Fisher 1098 EGR, Itron, and FNAC 7218-4 providing precise, durable pressure control for safe and efficient burner operation.
• Industrial Blowers Industrial-grade combustion-air and general air-handling blowers from Airpro, Northern Blower, Chicago Blower, and FNAC, supplied in any arrangement per application.
• Waste Heat Recovery Systems (HRSG / Economizers / Air Preheat) Heat Recovery Steam Generators (HRSG), economizers, and air-preheat systems that capture waste heat from exhaust gases to improve process efficiency and reduce fuel consumption.
• CSA Approved Safety Shut-Off and Isolation Valves CSA-approved manual and automatic safety shut-off and isolation valves (WGI manual, VCI automated, Siemens VGG) in stainless and carbon steel, available in motor- or pneumatically-actuated variants with proof-of-closure switches.
• Custom Air Flow Metering System (Venturi) Custom-designed venturi airflow meters for precise measurement and control of combustion airflow, tailored to specific application requirements.
• Digital Temperature Controllers Pre-programmed digital temperature and limit controllers from Yokogawa, Honeywell UDC, and Omron, used for combustion and process-control applications.
• Control Valves and Ratio Regulators Control valves and ratio regulators from Dynaflo, Fisher, Rotork, and Samson, plus Nucom electric actuators and air dampers, for simple cost-effective gas/air ratio control and precise fluid-flow regulation.
• Field Services (Commissioning, Combustion Analysis, Maintenance) Field services including commissioning and start-up of fired equipment (with operator training and CSA field approvals), flame-safeguard troubleshooting and root-cause analysis, combustion analysis and process tuning (emissions, stack oxygen, NOx), and preventative maintenance for critical process furnaces and burner controls.

Quantifiable outcome

• First orders of PILLARD NANOxFLAM burners into the North American market placed by a large Canadian Oilsands producer
• +2 more outcomes

Segments7 records

Ideal customer profiles3 records

Technology focussed Yes

API detail

Has API

No

API docs

API detail

Core technology

AI maturity

App detail

Integration24 records

Feature6 records

Partnerships

Six partnerships are on record, tiered flagship / core, core and minor.

• Fives (Fives Combustion / Fives Pillard / Fives North American Combustion)flagship / coreStrategic or Co-development PartnerFives is a recognized name in combustion technology and process heating solutions, with global sales and operations. PCSI partnered with Fives North American Combustion to implement cutting-edge Lean Premix Ultra Low NOx burner technology in Canada's potash industry. Fives Pillard also co-implemented the PILLARD NANOxFLAM burner technology with PCSI for a large Canadian Oilsands producer — one of the first such installations in North America.
• FireyecoreTechnology or IntegrationFireye is a leading manufacturer of flame safeguard controls and burner management products. PCSI integrates Fireye products (e.g., Burner Logix YB110/YB230, Micro M, E100 Flame Monitor, 45UV5/55UV5/65UV5 scanners) into its burner management and combustion safety solutions.
• E-Tech Heat Recovery ProductscoreTechnology or IntegrationE-Tech provides waste heat recovery and heat exchanger solutions, and is also an authorized Kentube Engineered Products Manufacturer. PCSI integrates and supplies E-Tech waste heat recovery and heat recovery steam generator (HRSG) products as part of its energy-efficiency solutions.
• Victory EnergycoreTechnology or IntegrationVictory Energy is an industry-leading solutions provider for boilers and burners, listed as a technology partner on PCSI's website. PCSI supplies Victory Energy solutions as part of its boiler/burner portfolio.
• DCM Group (DCM Integrated Solutions)flagship / coreStrategic or Co-development PartnerDCM Group is PCSI's parent organization / acquirer. Through integration with the DCM Group, PCSI delivers its expertise and engineered combustion solutions alongside a strong, growth-oriented organization well established across Canada. President & CEO Rob Dowler (DCM) and Shane Hay (PCSI) publicly endorsed the partnership.
• TES GroupminorStrategic or Co-development PartnerTES Group is listed as an affiliate company on PCSI's website, part of the broader DCM-affiliated ecosystem.

Scale indicators7 records

Recent moves6 records

Expansion highlights4 records

Regional players

• Weishaupt: Weishaupt is a leading German manufacturer of industrial burners, burner management systems, and combustion technology with global reach but a primary footprint in Europe. It is comparable to PCSI's burner technology and target applications but operates primarily outside PCSI's North American core market.

Direct peers

• Eclipse Combustion: Eclipse designs and manufactures industrial burners and combustion systems for process heating. It is comparable to PCSI in custom-engineered burner offerings and target industrial process heating applications.
• Fives (Fives Combustion / Fives Pillard): Fives is a global combustion technology OEM whose Pillard NANOxFLAM Ultra Low NOx burners are co-implemented with PCSI in Canadian oilsands and potash applications. Fives is both a partner and the most direct technology-level peer, competing for the same custom-engineered industrial burner programs.
• Hauck Manufacturing Company: Hauck Manufacturing produces industrial burners and combustion systems for process industries, including waste heat recovery and ultra-low NOx solutions. It is a direct peer to PCSI's custom-engineered burner portfolio in mining, steel, and process heating.
• Victory Energy: Victory Energy supplies industrial boilers and burners and is listed as a PCSI technology partner. It competes head-to-head with PCSI in boiler burner retrofits, package boilers, and custom-engineered fired equipment for industrial customers.
• Maxon (a business of Honeywell): Maxon supplies industrial burners, shut-off valves, and combustion control equipment. It competes with PCSI on custom-engineered burner packages and gas train components for process industries.

Broad incumbents

• Honeywell Process Solutions (Combustion Controls): Honeywell supplies burner management systems, flame safeguard controls (e.g., 7800L), and digital temperature controllers that PCSI integrates. As a broad incumbent, Honeywell's combustion controls portfolio overlaps with PCSI's BMS and control upgrade offerings for large industrial customers.
• Babcock & Wilcox (B&W): B&W is a global incumbent in industrial power boilers and combustion equipment, referenced as an industry-leading supplier PCSI works with. It competes with PCSI on large industrial boiler and boiler house projects across mining, oil & energy, and utilities.
• Dürr AG / Clean Technology Systems: Dürr, through its Clean Technology Systems business, supplies industrial burner technology including Ultra Low NOx solutions for process industries. It is a broad incumbent competing in the same custom-engineered combustion space as PCSI at larger scale.
• Cleaver-Brooks: Cleaver-Brooks is a major North American manufacturer of packaged boilers, burners, and combustion control systems. It directly competes with PCSI's Boiler Burners & Retrofits and Burner Management Systems lines across industrial and institutional customers.

Market position

Strengths5 records

Weaknesses5 records

Competitive moat5 records

Key risks5 records

Key highlights7 records

Customer concentration

• Facebookfacebook.com/Process-Combustion-Systems-Inc-156004394498658
• LinkedInlinkedin.com/company/process-combustion-systems-inc

Compliance3 records

Revenue estimate

Valuation estimate

Number of profiles

Profiles1 record

Subsidiaries1 record

Funding overview

Funding rounds

Investors

Funding detail is available on the Subscription and Enterprise plan.Contact sales →

M&A

Investments

M&A and investment is available on the Subscription and Enterprise plan.Contact sales →

Frequently asked questions about Process Combustion Systems