In the sintering process, a curtain flame burner ignites the sinter bed’s top layer, fusing iron ore particles into porous sinter as input materials for blast furnaces. The burner tip of a curtain flame burner system at Sinter Plant-1, DSP, Durgapur, is lined with refractory castable. However, excessive heat damages the burner tips lined with refractory material, requiring its replacement every six months. To improve durability, precast prefabricated (PCPF) andalusite-based 60% alumina burner blocks were developed, offering high resistance to thermal spalling. These prefabricated blocks, fired at 1450 °C, replaced the in situ refractory casting, extending the burner tips' lifespan. The burner design was modified to incorporate fewer nozzles and a swirling flame pattern to protect the impact area and broaden flame coverage. Prefabricated blocks were installed with locking pins, ensuring durability and easy transportation. These PCPF blocks are expected to last over two years, reducing operational downtime and improving efficiency. The blocks were successfully installed and tested, demonstrating improved thermal performance and resistance to expansion and cracking under high temperatures.