Energy inputs and its environmental effects are critical to a thermal process. The increased use of fossil fuel based energy resources has become increasingly important, particularly in developed countries and increasingly in the developing countries. So there is need to use the existing source of energy in most efficient way. The complete burning of fuel is very important for uniform distribution of heat energy and less NOx formation. Numerical study has done to design an air distributor in a regenerative burner for proper mixing of air and fuel. Different configurations of air distributor were analyzed with respect to control of flame temperature, low NOx formation and less pressure development inside furnace. An air distributor unit with its holes of size 4mm in diameter, distributed at an angle of 15 degree was found best in regard of low pressure and low NOx formation which were calculated at the outlet of furnace.
