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Title:
CYCLONIC BURNER WITH SEPARATION PLATE IN THE COMBUSTION CHAMBER
Document Type and Number:
WIPO Patent Application WO/2011/006235
Kind Code:
A1
Abstract:
A method and apparatus for burning fuel are described In a conventional boiler the combustion process produces particles which form a layer of deposits on boiler tubes, thus reducing heat transfer efficiency A fuel burner (100) includes a casing, a combustion chamber (106), a tangential gas inlet (108), a fuel delivery system (112) and an exhaust port (114) The casing includes a lower wall (102), an upper wall (104) and a cylindrical side wall (105) formed between the lower and upper walls (102, 104) and encloses the combustion chamber (106) The tangential gas inlet (108) is formed in the cylindrical wall (105) of the combustion chamber (106) The fuel delivery system (112) is configured to deliver fuel into the tangential air inlet (108) The exhaust port (114) is formed in the upper wall (104) of the combustion chamber (106) Gas is delivered into the combustion chamber (106) at a velocity and flow rate and mixes with fuel delivered from the fuel delivery system (112), such that a clean flame burns in the combustion chamber (106) A clean flame is a flame substantially free of unburned particulate matter.

Inventors:
HAYNES HAROLD (CA)
Application Number:
PCT/CA2010/001043
Publication Date:
January 20, 2011
Filing Date:
July 08, 2010
Export Citation:
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Assignee:
STAR FIRE COMB SYSTEMS INC (CA)
HAYNES HAROLD (CA)
International Classes:
F23C3/00; F23C7/00; F23D1/02; F23D14/02; F23L1/00
Foreign References:
US3199476A1965-08-10
US20030194671A12003-10-16
US4003691A1977-01-18
US5029557A1991-07-09
Attorney, Agent or Firm:
COLLARD, Christine, J. et al. (World Exchange Plaza100 Queen Street, Suite 110, Ottawa Ontario K1P 1J9, CA)
Download PDF:
Claims:
CLAIMS:

1. A burner comprising:

a casing comprising a lower w all, an upper w all and a cylindrical side w all formed between the lower and upper w alls and enclosing a combustion chamber;

the combustion chamber;

a tangential gas inlet formed in the cylindrical w all of the combustion chamber; a fuel deliver} system configured to deliver fuel into the tangential air inlet; and an exhaust port formed in the upper wall of the combustion chamber;

w herein gas is delivered into the combustion chamber at a velocity and flow rate and mixes w ith fuel delivered from the fuel deliver} system such that a clean flame burns in the combustion chamber, where a clean flame is substantial!} free of unburned particulate matter.

2. The burner of claim 1, wherein the fuel deliver} system is configured to deliver fuel into a gas stream in the tangential gas inlet upstream of a gas entrance into the combustion chamber.

3. The burner of claim 1, wherein the exhaust port includes a sleeve extending substantially perpendicularly relative to the upper wall of the combustion chamber. 4. The burner of claim 1, wherein a width of the combustion chamber is at least two times a height of the combustion chamber.

5. The burner of claim 1, wherein a width of the exhaust port is in the range of approximately 1A to 1A a diameter of the combustion chamber.

6. The burner of claim 1, wherein the fuel deliver} system includes a nozzle to spray the fuel into the tangential inlet.

7. The burner of claim 1. further comprising:

a second fuel deliver} system configured to deliver a primary fuel downstream of the fuel delivered by the fuel deliver} system, wherein the fuel delivered by the fuel deliver} system is a pilot fuel.

8. The burner of claim 7, wherein the primary fuel is gravity fed into the combustion chamber and the second fuel deliver} system comprises a conveying system.

9. The burner of claim 1. wherein the gas delivered into the combustion chamber is air.

10. A method of burning fuel comprising:

introducing a fuel into a tangential gas inlet formed in a cylindrical w all of a casing comprising a lower w all, an upper w all, the cylindrical side w all formed between the lower and upper w alls to enclose a combustion chamber and an exhaust port formed in the upper w all, w here the fuel is introduced into a gas stream in the air inlet upstream of an entrance into the combustion chamber; and

delivering gas into the combustion chamber through the tangential gas inlet to mix with the fuel, where the gas is delivered at such a velocity and flow rate that a clean flame burns in the combustion chamber, the clean flame being substantial!} free of any unburned particulate matter.

11. The method of claim 10, further comprising:

delivering a primary fuel into the combustion chamber downstream of the fuel, wherein the fuel is a pilot fuel.

12. A boiler comprising:

a plurality of boiler tubes in fluid communication w ith a firebox;

the firebox; and

a burner contained within the firebox, the burner comprising:

a casing comprising a lower w all, an upper w all and a cylindrical side w all formed between the lower and upper walls to enclose a combustion chamber;

a tangential gas inlet formed in the cylindrical w all of the combustion chamber;

a fuel deliver} system configured to deliver fuel into the tangential gas inlet; and

an exhaust port formed in the upper wall of the combustion chamber;

wherein gas is delivered into the combustion chamber at a velocity and flow rate and mixes with fuel delivered from the fuel deliver} system such that a clean flame substantially free of any unburned particulate matter burns in the combustion chamber; wherein, radiant heat from the burner heats the firebox and exhaust gas expelled from the exhaust port provides convection heat to the boiler tubes.

13. A burner comprising:

a combustion chamber comprising:

a lower wall,

an upper w all,

a cylindrical side w all formed between the lower and upper w alls to enclose the combustion chamber,

a plate separating the combustion chamber into a lower chamber and an upper chamber, where an annular gap is provided between the plate and the cylindrical w all providing communication between the lower and upper chambers;

a tangential gas inlet formed in the cylindrical ΛΛ all of the combustion chamber; a fuel deliver} system configured to deliver fuel into the tangential gas inlet; and an exhaust port formed in the upper w all of the combustion chamber.

14. The burner of claim 13, wherein gas is delivered into the combustion chamber at a velocity and flow rate and mixes w ith fuel delivered from the fuel deliver} system such that a clean flame substantial!} free of unburned particulates burns in the combustion chamber. 15 The burner of claim 13, wherein the tangential gas inlet terminates in an air entrance into the low er chamber

16 The burner of claim 13, wherein the plate is suspended from the upper w all of the combustion chamber

17 The burner of claim 13, wherein the plate is supported b} one or more support members extending to the low er w all of the combustion chamber 18 The burner of claim 13, wherein the plate includes one or more apertures, each aperture in fluid communication with a gas supph and wherein gas is pro\ided to the combustion chamber through the one or more apertures

19 The burner of claim 18, w herein the gas is air

20 The burner of claim 18, wherein the one or more apertures are on formed in an upper surface of the plate and gas is pro\ided into the upper chamber of the combustion chamber 21 The burner of claim 18, w herein the one or more apertures are formed in a low er surface of the plate and gas is pro\ided into the low er chamber of the combustion chamber

22 The burner of claim 18, wherein the one or more apertures are formed in an edge of the plate facing the α lindπcal w all of the combustion chamber and gas is pro\ ided into the annular gap betw een the plate and the c\ lindπcal w all

23 The burner of claim 18, further comprising one or more gas directing members positioned on the plate o\ er each of the one or more apertures, the gas directing members pro\iding a channel with an outlet to direct the flow of gas from the apertures into the combustion chamber

24. The burner of claim 23, wherein each gas directing member comprises a first component extending substantially perpendicular to the plate and a second component extending substantially parallel to the plate w here a distal end of the second component comprises the outlet.

25. The burner of claim 13, further comprising a second plate positioned between the plate and the lower wall of the combustion chamber with an annular gap between the second plate and the cylindrical w all, where the second plate separates the lower chamber into a first lower chamber and a second lower chamber.

Description:
CYCLONIC BURNER WITH SEPARATION PLATE IN THE COMBUSTION CHAMBER

TECHNICAL FIELD

This in\ ention relates to a method and apparatus for burning fuel

BACKGROUND

A com entional boiler uses the combustion of a fuel, such as w ood. coal, oil or natural gas, to generate a flame that burns w ithin the boiler ' s firebox Generalh , the fuel burning mechanism sits outside the firebox and the flame is directed into the firebox The flame is usualh a } ellow or orange flame and the combustion process produces particles of incandescent carbon in the exhaust gas stream These particles can create carbon deposits on the boiler tubes and flues pro\ iding an undesirable insulating la} er that can greath reduce boiler efficienα The boiler is but one example of burner applications w here particles in the exhaust gas due to inefficient fuel burning Λ ield undesirable effects

SUMMARY

This in\ ention relates to a method and apparatus for burning fuel In general, in one aspect, the in\ ention features a burner including a casing, a combustion chamber, a tangential gas inlet, a fuel deh\ en SΛ stem and an exhaust port The casing includes a low er w all, an upper w all and a α lindπcal side w all formed betw een the low er and upper w alls and encloses the combustion chamber The tangential gas inlet is formed in the CΛ lindrical w all of the combustion chamber The fuel deh\ en SΛ stem is configured to deh\ er fuel into the tangential air inlet The exhaust port is formed in the upper w all of the combustion chamber Gas is deh\ ered into the combustion chamber at a \ elocit} and flow rate and mixes w ith fuel deh\ ered from the fuel deln en SΛ stem, such that a clean flame burns in the combustion chamber A clean flame is a flame substantial!} free of unburned particulate matter

Implementations of the in\ ention can include one or more of the following features The fuel deh\ en s} stem can be configured to deh\ er fuel into a gas stream in the tangential gas inlet upstream of a gas entrance into the combustion chamber The exhaust port can include a slee\ e extending substantialh perpendicularh relatπ e to the upper ΛΛ all of the combustion chamber. A width of the combustion chamber can be at least two times a height of the combustion chamber. A width of the exhaust port can be in the range of approximately 1 A to 1 A a diameter of the combustion chamber. The fuel deliver} system can include a nozzle to spray the fuel into the tangential inlet. The burner can further include a second fuel deliver} system configured to deliver a primary fuel downstream of the fuel delivered by the fuel deliver} system, where the fuel delivered by the fuel deliver} system is a pilot fuel. The primary fuel can be gravity fed into the combustion chamber and the second fuel deliver} system can be a conveying system. The gas delivered into the combustion chamber can be air.

In general, in another aspect, the invention features a method of burning fuel. The method includes introducing a fuel into a tangential gas inlet formed in a cylindrical w all of a casing of a burner. The casing includes a lower w all, an upper w all, and the cylindrical side w all formed between the lower and upper w alls to enclose a combustion chamber and an exhaust port formed in the upper wall. Fuel is introduced into a gas stream in the air inlet upstream of an entrance into the combustion chamber. The method further includes delivering gas into the combustion chamber through the tangential gas inlet to mix w ith the fuel. The gas is delivered at such a velocity and flow rate that a clean flame burns in the combustion chamber, the clean flame being substantial!} free of any unburned particulate matter.

In some implementations, the method can further include delivering a primary fuel into the combustion chamber downstream of the fuel, in instances where the fuel is a pilot fuel.

In general, in another aspect, the invention features a boiler. The boiler includes multiple boiler tubes in fluid communication w ith a firebox, the firebox, and a burner contained within the firebox. The burner includes a casing having a lower w all, an upper w all and a cylindrical side w all formed between the lower and upper w alls to enclose a combustion chamber. The burner further includes: a tangential gas inlet formed in the cylindrical wall of the combustion chamber; a fuel deliver} system configured to deliver fuel into the tangential gas inlet; and an exhaust port formed in the upper wall of the combustion chamber. Gas is delivered into the combustion chamber at a velocity and flow rate and mixes w ith fuel delivered from the fuel deliverv SΛ stem, such that a clean flame substantialh free of any unburned particulate matter burns in the combustion chamber. Radiant heat from the burner heats the firebox and exhaust gas expelled from the exhaust port provides convection heat to the boiler tubes.

In general, in another aspect, the invention features a burner including a combustion chamber, a tangential gas inlet, a fuel deliver} system and an exhaust port. The combustion chamber includes: a lower w all, an upper w all, a cylindrical side w all formed between the lower and upper w alls to enclose the combustion chamber, and a plate separating the combustion chamber into a lower chamber and an upper chamber. An annular gap is provided between the plate and the cylindrical w all providing

communication between the lower and upper chambers. The tangential gas inlet is formed in the cylindrical wall of the combustion chamber. The fuel deliver} system is configured to deliver fuel into the tangential gas inlet. The exhaust port is formed in the upper w all of the combustion chamber.

Implementations of the burner can include one or more of the following features. The gas can be delivered into the combustion chamber at a velocity and flow rate and mix Λλith fuel delivered from the fuel deliver} system, such that a clean flame substantial!} free of unburned particulates burns in the combustion chamber. The tangential gas inlet can terminate in an air entrance into the lower chamber. The plate can be suspended from the upper wall of the combustion chamber, or the plate can be supported by one or more support members extending to the lower w all of the combustion chamber.

The plate can include one or more apertures, each aperture in fluid communication with a gas supply and wherein gas is provided to the combustion chamber through the one or more apertures. The gas can be air. The apertures can be formed in an upper surface of the plate and gas can be provided into the upper chamber of the combustion chamber and/or the apertures can be formed in a lower surface of the plate and gas can be provided into the lower chamber of the combustion chamber. The apertures can be formed in an edge of the plate facing the cylindrical wall of the combustion chamber and gas can be provided into the annular gap between the plate and the cylindrical w all.

Gas directing members can be positioned on the plate under or over each of the one or more apertures, where the gas directing members provide a channel with an outlet to direct the flow of gas from the apertures into the combustion chamber. A gas directing member can include a first component extending substantially perpendicular to the plate and a second component extending substantially parallel to the plate, where a distal end of the second component comprises the outlet. The burner can further include a second plate positioned between the plate and the lower wall of the combustion chamber, with an annular gap between the second plate and the cylindrical w all. The second plate can separate the lower chamber into a first lower chamber and a second lower chamber.

Implementations of the invention can realize one or more of the following advantages. The burner provides both radiant heat and heated exhaust gases. The radiant heat emitted from the burner can be estimated and therefore controlled by controlling the dimensions of the burner and/or operating parameters. Placing the burner within the firebox of a boiler, for example, provides for improved heat management and boiler efficiency. The clean flame burning within the burner provides for substantially clean exhaust gases, and therefore less harmful emissions. In the boiler application, this can mean improved boiler efficiency and less boiler down-time to remove carbon build-up from boiler tubes and flues, as required by a conventional burner unit. The burner can be configured to burn oil sands products as a fuel. Using the burner within a boiler used for steam assisted bitumen recover} from an oil sands reservoir can be particularly efficient when using readily available oil sands products as a fuel feedstock, and avoiding the use of more expensive natural gas as the major fuel for steam generation.

Another advantage is the opportunity to exploit less expensive available fuel feedstock, even a feedstock still contained in the oil sands prior to any treatment or processing. Another advantage is the ability to switch to a different fuel on an almost instant basis. This can be particularly advantageous w ith fuel prices constantly changing. For example, the price differential between natural gas and oil fluctuates considerably, which can be strong motivator in selecting a fuel type. As prices change, the fuel type can be changed accordingly to minimize fuel costs.

The details of one or more embodiments of the invention are set forth in the accompanying drawings and the description below. Other features, objects, and advantages of the invention will be apparent from the description and drawings, and from the claims. DESCRIPTION OF DRAWINGS

FIG lA is a plan \iew of an example burner

FIG IB is a cross-sectional side \iew of the burner of FIG IA

FIG 2 is a flow chart show ing an example process for using a burner

FIG 3 A is a plan \ lew of an example burner including a \ apoπzer plate

FIG 3B is a cross-sectional side \ iew of the example burner of FIG 3 A

FIG 4A is a cross-sectional side \ lew of an alternate e \ apoπzer plate

FIG 4B is a perspectπ e \ lew of an upper surface of the alternate e \ apoπzer plate of FIG 4A

FIG 4C is a perspectπ e \ lew of a low er surface of the alternate e \ apoπzer plate of FIG 4A

FIG 4D is a cross-sectional side \ lew of another alternate e \ apoπzer plate FIG 5A is a cross-sectional side \iew of an example burner including a rake assembh

FIG 5B is a cross-sectional top \iew of the burner of FIG 5A

FIG 5C is a cross-sectional \iew of a blade included in the rake assembh shown in

FIGS 5A and 5B

FIG 5D is a cross-sectional side \iew of a burner including a chute

FIG 5E is a top \ lew of the burner of FIG 5D

FIG 5F is a cross-sectional side \ lew of an alternate e burner

FIG 6A is a cross-sectional side \ lew of a prior art example of a boiler

FIG 6B is a cross-sectional side \iew of a boiler using a burner within the firebox

Like reference SΛ mbols in the \ anous drawings indicate like elements DETAILED DESCRIPTION

Methods and apparatus for burning a fuel are described wherein burn efficiena is enhanced such that exhaust gases are substantial!} free of particulates Referring to FIGS IA and IB, one example embodiment of a burner 100 is shown. FIG IA show s a plan \ lew and FIG IB show s a cross-sectional front \ lew The burner has a casing including a low er w all 102, an upper w all 104 and a α lindπcal side w all 105 formed betw een the low er and upper w alls to enclose a combustion chamber 106 The burner 100 includes a gas inlet 108 In this implementation, the gas inlet 108 is a tangential air inlet terminating at an air entrance 110 into the combustion chamber A fuel deh\ en SΛ stem 112 is positioned to delrv er fuel into the air stream within the air inlet and upstream of the air entrance 110 In other implementations, the fuel deh\ en SΛ stem can be positioned downstream of the air entrance 110 An exhaust port 114 is formed in the upper w all 104 of the burner 100 Although in the particular implementation described, air is input into the burner through the gas inlet 108, it should be understood that pure OXΛ gen or another gas mixture w ith some content of OXΛ gen can be used instead, and air is but one example of the inlet gas for illustratn e purposes

The CΛ lindrical shape of the combustion chamber 106 pro\ides an intimate sustained containment of the fuel-air mixture and the mixture can circulate repeatedh around the interior of the combustion chamber before exhausting The air stream input into the combustion chamber 106 through the gas inlet 108 pro\ides OXΛ gen for substantialh complete combustion of the fuel, but also pro\ides sufficient kinetic energ} such that adequate mixing and turbulence w ithin the combustion chamber 106 is achie\ ed The fuel can be substantialh , if not completely , \ aponzed within the combustion chamber 106 The CΛ lindrical shape of the combustion chamber 106 allow s the flame to be re- circulated and reα cled. such that the increased residence time promotes complete combustion of the fuel, i e , a clean burn

The air is deh\ ered into the combustion chamber 106 w ith a direction. \ olume, pressure and \ elocitΛ such that the fuel burns with a clean flame that is substantialh free of unburned fuel The clean flame is t} picalh characterized b} a blue flame resembling a blue plasma, that substantialh fills the combustion chamber with a comparatπ eh small crow n of blue flame e\ ident at the exhaust port That is, a ΓΛ pical orange or Λ ellow flame is indicatn e of unburned fuel, that is, unburned incandescent particles of fuel or carbon w ithin the flame How e\ er, if combustion of the fuel is complete (or substantialh complete), the flame burns blue The blue color of the flame is indicatn e of complete or substantialh complete fuel combustion, i e , a "clean flame " In some implementations, it is desirable to achie\ e a clean flame at a low est possible temperature For example, although a blue/clean flame can be achie\ ed from an ox\ -acetΛ lene torch, the temperature of the flame is approximate!} 5500° Celsius, which can be destructπ e to the burner 100, or require the use of appropriate heat resistant material in the construction of the burner The temperature required to achie\ e a clean flame can \ an depending on the fuel being burned, how e\ er, in some implementations, a clean flame has been achie\ ed at approximate^ 800° Celsius

The operating parameters, such as, \ olume, pressure and \ elocit} . required to achie\ e the clean flame can be obtained empiricalh through experimentation and can \ an w ith \ an ing burner configurations and dimensions The air \ olume can be extrapolated based on the manufacturer ' s specifications of a blow er used to blow the air into the burner The pressure can be measured at one or more points, for example, w ith a w ater tube nanometer The pressure measuring de\ ιce(s) can be positioned in \ aπous locations, including in a priman air supph tube ahead of the burner entrance, in the peπphen (outside edge) of the combustion chamber to measure pressure in this high \ elocit} region, and/or near the center of the combustion chamber to measure pressure close to the center of the flame inside the burner, which pressure can be compared to pressures measured at the other locations Such pressure readings w ill t} picalh be abo\ e normal atmospheric pressure and can represent the addition of energ} to the air stream and the effects of fuel combustion

The \ elocit} can be determined (or at least estimated) based on a measuring instrument gauging the \ elocit} of air in the burner before being lit and then a factor added for the \ olumetric increase when the flame is burning Operating parameters can be adjusted until the flame switches from an orange/} ellow flame to a blue flame indicating a clean burn The \ olume, pressure and \ elocit} required to achie\ e the clean flame can be recorded In other implementations, the \ olume, pressure and \ elocit} required to achie\ e the clean flame can be determined b} modeling, e g , computer modeling

The tangential gas inlet 108 produces an air pattern within the combustion chamber

106 that effectn el} punches a "round hole " (in the case of a round air inlet) of high \ elocit} air into the fuel-air mixture alread} in the combustion chamber 106 This plug of high \ elocit} air rapidh flattens out against the inner surface of the c} lindrical side w all 105 and pro\ides continuous acceleration of the air content within the combustion chamber 106 The highest air pressure is against the peπphen of the burner casing, w ith a somew hat low er pressure at the centre of the combustion chamber 106 The fuel deh\ ered into the air stream, e g , b} gra\ it} or spra} , is forced b} centrifugal action against the hot interior faces of the casing w here the fuel is rapidh brought up to combustion temperature and substantial!} \ apoπzed and mixed w ith the entraining air

Visual observ ations of some implementations ha\ e shown the flame to make approximate!} 6-8 complete re\ olutions inside the combustion chamber 105 with the high speed flame concentrated in a "dense " la} er around the inner face of the c} lindrical w all 105, as can be indicated during experimentation b} glowing incombustible particles (e g , bits of steel, w elding slag and/or gπndings) For example, the \ elocit} can be in the order of approximate!} 40 feet per second It should be understood that different

implementations ma} exhibit different beha\ ior and the abo\ e is intended as an illustratn e example

The residence time, rec} cling and recirculation of the flame and fuel within the confined and contained space of the combustion chamber are operating parameters that can achie\ e the clean burn and generate a clean, blue flame with complete combustion of the fuel That is, being able to contain the flame and adjust the residence time can achie\ e a clean flame The residence time can be adjusted to suit a particular application and fuel being used, for example, b} changing the height and diameter of the burner and/or b} using one or more plates to separate the interior of the burner into tw o or more combustion chambers

To achie\ e a relatπ eh eas} start-up and stable combustion, a balance can be achie\ ed betw een the temperature of the casing, such that it is sufficienth hot for good fuel \ apoπzation, and the cooling effect of the combustion air entering the combustion chamber 106

When the burner is operating at clean flame conditions, the temperature within the combustion chamber in some implementations (e g , depending on the fuel burned), can be approximatel} 800 0 C In an embodiment w here the surfaces and w alls of the burner are made from steel, the temperature of the steel during clean flame operating conditions can be in the range of approximatel} 650° C to 760° C with the casing glowing a dull red, to as high as approximatel} 1200° C with the casing glowing a bright chern red, emitting radiant heat The temperature of the casing \ aπes w ith the amount of fuel burned w ithin the combustion chamber o\ er a certain time span As the fuel sw iris w ithin the combustion chamber by centrifugal force, any unburned fuel coming into contact with the inner w alls of the combustion chamber 106 is vaporized.

In the embodiment shown in FIGs. IA and IB, the exhaust port 114 has a circular shape and is formed in the upper wall 104 of the burner 100. In some examples, the diameter of the exhaust port 114 can be approximately 1 A to 1 A the diameter of the combustion chamber 106. The exhaust port 114 can include a sleeve inserted into the port opening. The sleeve can alter the aerodynamics of the combustion process. For example, in some implementations, the sleeve can extend down into the combustion chamber 106, which can increase the pressure within the chamber. In other implementations, the sleeve can extend up from the upper wall 104, which can provide an exhaust stack effect that can increase the velocity of the flame within the chamber. In other implementations, the sleeve can extend both down into the chamber and up from the upper wall. Preferably the exhaust port is circular and centered. In some implementations, the exhaust port can be formed in the lower wall 102 of the casing rather than the upper wall 104.

In some implementations, the fuel deliver} system 112 can drip feed a liquid fuel into the air inlet. Examples of fuel include, but are not limited to, diesel, #6 fuel oil, canola oil, propane, natural gas, and biofuels or any combination of these or other fuels. It is possible, and in some instances desirable from an availability and/or fuel cost perspective, to switch fuels without shutting down or reconfiguring the burner. This ease of fuel switching can be parti cularly advantageous for certain potential applications of the burner, such as combined cycle electrical power generation, or in a residential heating application.

In other implementations, the fuel deliver} system 112 can include a nozzle that sprays the fuel into the air stream. A metered fuel deliver} system can be used, for example, where the fuel is introduced through a fixed displacement pump and the volume of fuel is constant for any given pump RPM (revolutions per minute) and nozzle size. In another example, fuel deliver} can be ultrasonic where extremely fine atomization is achieved and the fuel/water blending can be at a ratio of, in one example, 30% water and 70% fuel. Other fuel deliver} systems are possible, and these are but a few examples.

In some implementations, the burner 100 can include a second fuel deliver} system positioned and configured to deliver a primary fuel into the combustion chamber downstream of the fuel deliver} system 112, which can be used to deliver a pilot fuel. That is, the initial fuel delivered by the fuel deliver} system 112 can function as a pilot fuel, with the primary fuel providing the majority of the heating value. By w ay of example, in some implementations, the primary fuel can be a heavy end product extracted from oil sands, for example, coke or bitumen. In other implementations, the primary fuel can be an Orimulsion or can be MSAR fuel available from Quadrise Canada Corporation of Calgary, Canada. This can be advantageous, particularly if the burner is used to produce steam for a steam assisted operation to recover heavy oil or bitumen from the oil sands, as is described in further detail below.

Referring to FIG. 2, a flow chart shows an example process 200 for burning a fuel with reduced emissions. For illustrative purposes, the process 200 is described using the burner 100 shown in FIGS. IA and IB, although it should be understood that other configurations of burner can be used, for example, different implementations described further below. The velocity and flow rate at which the gas, air in this example, w ill be delivered into the combustion chamber is determined (Step 201). The velocity and flow rate are determined so that enough oxygen is present in the combustion chamber for a substantially complete and clean burn of the fuel without excess air, and are determined to provide sufficient kinetic energy so that adequate mixing and turbulence is achieved w ithin the combustion chamber.

The air is delivered into the combustion chamber 106 through the gas inlet 108 at the determined velocity and flow rate (Step 202). Fuel is introduced into the air stream upstream of the air entrance 110 into the combustion chamber using the fuel deliver} system 112 (Step 204). For example, the fuel can be drip fed or sprayed through a nozzle into the air stream. The fuel is ignited to initiate the fuel burn process (Step 206). In one implementation, a spark igniter can be used. For example, tw o electrodes can be positioned just downstream of the fuel being delivered into the air inlet and a spark across the gap betw een the tw o electrodes can ignite the fuel. Other sources or configurations of ignition can be used, e.g., a heated wire element mounted on ceramic posts.

In an implementation including a second fuel deliver} system for deliver} of a primary fuel, the primary fuel can be delivered into the combustion chamber 106, preferabh before the clean flame is achie\ ed (Step 208) In such an implementation, the fuel deh\ ered b} the fuel deh\ en SΛ stem 112 is a pilot fuel

After an initial w arm-up period expires, a determination is made that a clean flame has been achie\ ed ("Yes " branch of Step 210) For example, although a \ isual obseπ ation can pro\ ide a rough indication that a clean flame is achie\ ed. e g , the flame has turned to blue, in some implementations a flame sensor can be used The sensor can pro\ide a continuous feedback signal to a controller In one example, the sensor can be an ultra\ iolet sensor During clean flame operation, the ultra\ iolet sensor can be used and if the flame extinguishes, the sensor ceases generating a low \ oltage alarm current, which can then initiate a shutdown sequence In some implementations, tw o sensors can be used and a shutdown sequence is onh initiated if both sensors indicate the flame has extinguished In addition to detecting a flame-out condition, the sensor can continuoush measure the flame temperature, which can be transmitted to the controller pro\iding information about the combustion conditions and the burner efficienc}

In a boiler implementation, a three point control SΛ stem can be used that measures the burner, the FEGT (furnace exit gas temperature) and the boiler exit temperature Referring to FIG 6B, an illustratn e example of a boiler implementation is shown In some implementations, flame sensors can be positioned at some or all of the locations in the boiler 620 indicated b} reference numerals 640, 642 and 644 A flame sensor at 640 can "look " \ erticalh straight down into the centre of the burner A flame sensor at 642 can "look " down at an angle into the interior peπphen of the burner A flame sensor at 644 can "see " the exterior crown of the flame Other locations can be used, and the ones discussed are but a few examples

In addition to a flame sensor, a stack gas instrument can be used to measure the emissions from the burner, which information can be pro\ ided to the controller The emission measurements can be used to further determine ad)ustments to the operating parameters to achie\ e the clean flame

Referring again to FIG 2, if a clean flame is not present ("No " branch of Step 210), then one or more operating parameters can be adμisted until the clean flame is achie\ ed For example, the \ elocit\ and/or flow rate of the air and/or fuel being deh\ ered into the combustion chamber can be adμisted B\ w a> of illustration, if the flame is orange, the air flow can be increased or the fuel flow can be decreased If the flame is orange and unstable, there maj be too much air per fuel flow or the burner temperature ma} not Λ et be high enough for stable combustion In another example, the fuel/air mixture can be modified and/or the residence time of the flame in the burner can be modified, such that the proper conditions for achie\ ing the clean flame (i e , a blue flame) are achie\ ed

If a clean flame is present ("Yes " branch of Step 210), then in implementations using an optional pilot fuel (i e , where the fuel in step 206 is a pilot fuel), deh\ en of the pilot fuel can cease once the priman fuel is being deh\ ered and burned in the combustion chamber 106 (Step 212) How e\ er, in some implementations, depending upon the combustion characteristics of the priman fuel, the pilot fuel maj continue to be iniected into the burner The pilot fuel can be of a higher grade (e g , lighter \ ISCOSΠΛ ) than the priman fuel and therefore more expensn e As such, limiting the amount of pilot fuel required can be ad\ antageous Some non-limiting examples of a pilot fuel include natural gas, propane and diesel

In some implementations, a sensor can be used to detect if the flame has extinguished, as w as discussed abo\ e If the sensor detects the flame is out ("Yes " branch of Step 214), then the process loops back to the step of deln eπng the pilot fuel (Step 204), if deh\ en had ceased, or else the process loops back to the ignition step (i e , Step 206) In some implementations, a sensor can be used, e g , an ultra\ iolet temperature sensor, to detect the temperature of the exhaust gas If the exhaust gas temperature is too high or too low for a particular application of the burner ("Yes " branch of Step 216), then one or more operating parameters, e g , the \ elocitΛ . air flow rate, and/or fuel flow rate, can be adμisted until the desired temperature is reached, while maintaining a clean flame The process can continue until terminated, for example, b} a human operator, timer, or other mechanism (Step 218)

The burner 100 can be formed from a material capable of w ithstanding relatn eh high temperatures, for example, approximate!} 800 0 C Examples of materials include, but are not limited to. cast iron, steel including stainless steel, ceramic or ceramic-coated steel Preferabh , the w idth of the burner is greater than the height For example, the ratio of the w idth to the height can be 3 1 or 4 1 in some implementations The dimensions of the burner 100 can van \ depending on the application. In one illustrative example, the burner has a 15 inch diameter and is 8 inches tall. The diameter of the exhaust port is 6 3 Λ inches and the w alls of the burner are a 1 A inch thick. Other dimensions are possible, and these are but one example.

In some implementations, ultrasonic mixing can be used to mix, blend and inject the primary fuel into the burner. This can be parti cularly useful if the primary fuel is a heavy fuel, e.g., heavy oil or bitumen. Ultrasonic blending of the fuel can provide a stable emulsion of mixed water and fuel that can facilitate providing efficient combustion and lower flame temperature. In one example, the blended fuel can be 70% fuel and 30% water. Ultrasonic injection nozzles are also advantageous because of their open- tube characteristics, their tendency not to plug and the extremely fine atomization that can be achieved, which facilitates complete carbon burnout. In some implementations, ultrasonic vibration of internal burner elements can be used, which may promote better combustion, as is described further below.

Multi-Chambered Burner Implementation

Referring to FIGS. 3A and 3B, a plan view and cross-sectional side view of an alternative implementation of a burner 300 are shown. In this implementation, the combustion chamber is separated into an upper chamber 302 and a lower chamber 304 by a vaporizer plate 306. In this example, the vaporizer plate 306 is suspended by two or more support members 308 from an upper wall 310 of the burner 300. In other implementations, the plate 306 can be supported by one or more support members extending from the interior lower surface 316 of the burner, or one or more radial support members extending to the side wall 314.

In this implementation, the upper wall 310 includes a slanted portion 312 extending toward a cylindrical side wall 314. The cylindrical wall 314 joins the lower wall 316 to enclose the upper and lower combustion chambers 302, 304.

An annular gap 318 is provided between the vaporizer plate 306 and the cylindrical wall 314, thereby providing fluid communication between the upper and lower chambers 302, 304. In this implementation, the air entrance 319 from the air inlet 321 delivers the air stream into the lower chamber 304. Similarly, the fuel is provided upstream of the air entrance 319 into the air stream, and therefore the air/fuel mixture first encounters the lower chamber 304. The plate 306 can be formed from a heat resistant material, for example, stainless steel or ceramic although other material can be used. The heat within the lower chamber 304 can heat the plate 306 to glow red hot, for example, at a temperature in the range of approximately 65O 0 C to 825 0 C. The radiant heat emitting from the plate 306 along with the direct heat provided to unburned fuel contacting the surface of the plate 306 enhances vaporization of the fuel in the lower chamber 304. That is, the plate 306 increases the surface area the fuel within the burner of a given volume is exposed to and thereby improves the vaporization.

The dimensions of the burner 300 can vary, depending on the application. In one illustrative example, the burner has a 15 inch diameter and is 8 inches tall. The diameter of the exhaust port is 6 3 Λ inches and the w alls of the burner are a '/_. inch thick. The vaporizer plate is positioned 3 Vi inches above the lower w all. Other dimensions are possible, and these ones are but one example.

Referring to FIGS. 4A-4C, a schematic representation of an alternative

embodiment of the vaporizer plate is shown. FIG. 4A shows a cross-sectional side view, FIG. 4B shows a perspective top view, and FIG. 4C shows a perspective bottom view of the vaporizer plate 320. In this embodiment, the plate 320 is fluidlv connected to a secondary gas (air in this example) supply and includes an annular gap 328 along the circumference of the plate 320 from which air can be directed into the upper and/or lower chambers 302, 304. In the example shown, the plate 320 is hollow and includes a void 322 between an upper plate 324 and a lower plate 326.

The plate 320 can be mounted to the inner surface of the lower wall 316 of the burner 100, for example, on a pedestal. The pedestal can include an air flow line to direct the secondary air supply into the plate in the region 330. Other configurations can be employed to mount the plate 320 within the burner 100. The air enters the void 322 and is directed out of the annular gap 328 into the combustion chambers 302 and 304.

Referring to FIG. 4B, a perspective view of the upper surface of the plate 320 is shown. Curved slots are formed in upper and lower plates 324, 326 and fitted with vanes 340 that direct air exiting the plate 320 into a rapid spiral flow. Preferably, the plate 320 is configured such that the vanes 340 are orientated to direct the air into the rapid spiral flow in the same direction as a primary air supply, i.e., air introduced from air supply 321 through air entrance 319. The air exits the plate 320 radially at a high velocity and mixes with fuel and air vapors and the flame present in the low er combustion chamber 304. The secondary air supply can be controlled separately from the primary air supply and can provide a cooling function to the plate 320. FIG. 4C shows a perspective view of the lower surface of the plate 320. The lower surface can include an open region 330, which can be enclosed when the low er plate 326 is attached to a pedestal on which the plate can be mounted to the low er w all of the burner.

In other implementations, more or few er vanes 340 can be included in the plate 340, and the vanes can be configured differently than shown. For example, the curvature can be different than in the example show n, and/or the length of the vanes can be different.

In some implementations, the upper and lower plates 324, 326 are both

approximateh 6.5 millimetres thick and made of metal, for example, stainless steel, and the annular gap is approximately 2 millimetres in height. The vanes 340 can be formed from metal as w ell, for example, stainless steel. Other dimensions and materials are possible and those described here are for illustrative purposes.

Referring again to FIG. 4A, in some implementations, optionally ultrasonic energy can be transmitted to the vaporizer plate 320. An ultrasonic transducer 334 can provide ultrasonic transmissions to a transmission rod 332 that is positioned in approximately the center of the plate 320. The transmission rod 332 transmits ultrasonic energy to the plate 320 causing the plate to vibrate at a selected frequency. Vibrating the plate 320 can have beneficial effects on the combustion process. The transmission rod 332 can be encased within an air feed conduit providing air to the plate 320, and thereby be protected from the heat within the burner by the air flow w ithin the tube.

Referring to FIG. 4D, another alternative implementation of a vaporizer plate 360 is shown. In this implementation, air directing members 362 are positioned under apertures formed in a surface of the plate 360. In this example, the apertures are formed in the low er plate 364, although in other implementations, the apertures can be formed in the upper plate 366 or both plates. The air directing members 362 can have different configurations, depending on the desired air flow pattern. In this example, each air directing member 362 is formed as a 90° elbow , w ith the air outlets 368 directing the air stream in substantially the same direction as the air is delivered into the lower chamber 304 through the air entrance 319, thereby enhancing the vortex action of the air flow within the combustion chamber.

Providing additional air flow into the combustion chamber by way of the vaporizer plate can provide a mechanism whereby the flame characteristics can be improved at a later stage of combustion by providing an oxygen rich zone that can enhance complete or substantialh complete fuel burnout. In turn, the excess oxygen can facilitate the conversion of nitrogen oxide (NO) to nitrogen (N 2 ).

In some implementations, more than one vaporizer plate can be used to separate the combustion chamber into three or more chambers. For example, successive horizontal chambers can be formed between vaporizer plates. The successive chambers can be used to burn either the same primary fuel, or different fuels at the same time (e.g., the primary fuel and one or more secondary fuels), separately, or in sequence. By w ay of illustrative example in a three-chambered implementation, bitumen can be burned in a bottom chamber, a Number 6 fuel oil burned in a middle chamber and a diesel fuel or biodiesel fuel in an upper chamber. In other implementations, a secondary fuel can be burned in a single-chamber burner at the same time as the primary fuel.

Fuel Rake Assembly

In implementations of the burner using a primary fuel delivered into the combustion chamber in a solid or semi-solid phase, a fuel rake provided within the combustion chamber can facilitate air/fuel mixing and enhance the burn efficiency. For example, if the primary fuel is an oil sands product, the fuel (e.g.. heavy oil or bitumen) may be contained within sand and/or clay. The fuel-containing sand or clay can be ground or pulverized and blended to produce a somewhat homogeneous feedstock of primary fuel.

FIG. 5 A shows a cross-sectional view of an example burner 500 including a primary fuel deliver} system 502 and a rake assembly 504. In this example, the burner 500 includes a combustion chamber separated into an upper chamber 506 and a lower chamber 508 by a vaporizer plate 510. However, it should be understood that the rake assembly can be used in other implementations that do not include the vaporizer plate 510, that include more than one vaporizer plate and/or that include a differently configured vaporizer plate 510.

A pilot fuel deliver} system 512 is included for deliver} of the pilot fuel into the air stream being delivered into the lower chamber 508 through the primary air inlet 514. In the implementation shown, the primary fuel deliver} system 502 includes an auger to deliver the primary fuel feedstock into the lower chamber 508. Other configurations of primary fuel deliver} systems can be used. The force of the air stream and the cyclonic air action within the low er chamber 508 cause the primary fuel feedstock to swirl about within the lower chamber 508. The heat within the lower chamber 508 as well as the high temperature of the w alls and vaporizer plate 510 vaporizes the primary fuel contained within the feedstock. How ever, some of the feedstock in addition to non-combustible matter, e.g., sand or clay with the fuel burned from it. can accumulate on the inner surface of the low er w all 516 of the low er chamber 508.

In this implementation, the rake assembly 504 rotates about the center of the low er w all 516 of the low er chamber 508. The rake assembly 504 includes blades 518 configured to reach substantial!} to the inner surface of the low er chamber 504. In one example, the rake assembly 504 can be rotated (in the direction of arrow 505) at a low speed, e.g.. 10 to 15 revolutions per minute (RPM) by a rotation mechanism 520 positioned underneath the burner 500. In one embodiment, the rake assembly 504 rotates by way of a geared chain and sprocket electric drive, although other rotation mechanisms can be used. For example, a low -geared motor can drive the vertical drive shaft 522 to rotate the rake assembly 504 at a suitable speed. In some implementations, a relatively low speed, e.g., 5-50 revolutions per minute, is appropriate.

The rake assembly 504 includes blades 518 that can be airfoil shaped, as shown, in the cross-sectional view of a blade 518 in FIG. 5C, or can have a different configuration. In an implementation that is pressurized and cooled with combustion air, air jets can be provided on the blades, or a continuous narrow air slot can be provided, in the leading edge of the blades 518, blowing air in the same direction as the primary air inlet 514. The direction of air flow through and out of the blades 518 is represented by arrow s 524.

Referring to FIG. 5B, in some implementations, attached to the bottom of the blades 518 at various intervals can be short vertical tubes 525 terminating in scrapers 526, which may or may not be supplied with pressurized air. For example, as shown, the scrapers 526 can be each configured as a substantially triangular member with an air outlet directing air into the combustion chamber as represented by arrows 528. The scrapers 526 can further facilitate raking and agitating any accumulations of sand, clay (whether including unburned primary fuel or not) in the bottom of the lower chamber 508.

Supplying pressurized combustion air to the accumulations can facilitate releasing the primary fuel from the accumulations of sand or clay to be vaporized and burned higher within the combustion chamber. In the implementation shown, the scrapers 526 are staggered at different radial distances along the four blades 518, such that the circular paths traced by the scrapers 526 together cover all, or substantially all, of the inner surface of the lower wall of the burner 500. That is, the entire surface of the lower wall is scraped by the combined effect of the four scrapers 526. In some implementations, the scrapers 526 can be configured to lift and turn to vigorously agitate unburned primary fuel deposited on the inner surface of the lower wall of the burner, thereby exposing the unburned fuel to the air supply and enhancing the complete burning of the fuel.

Referring to FIG. 5D, a cross-sectional side view of an implementation of a burner 530 including an optional ejection system for "spent " non-combustible matter is shown. In this example, the ejection system is positioned in a lower, inner corner of the lower chamber, where non-combustible spent particles can be found traveling about the inner periphery of the lower chamber at high velocity. A chute 534 is provided to receive and trap the spent particles 535 as the} travel about the outer periphery. The particles can be collected, e.g., in a hopper 536, and later disposed of, for example, by an auger 540.

Optionally, the gases received in the chute can be re-injected into the burner through a vapor return duct 538.

FIG. 5E shows a top view of the burner 530 shown in FIG. 5D. In the

implementation shown, an optional door 544 can be formed in the cylindrical wall 546 of the burner 530 that can pivot between an open and a closed position. In the open position, the non-combustible spent particles can be received in the chute 534. In the closed position, the chute 534 is not in communication with the combustion chamber 532.

Preferably the height of the door 544 would be less than the total height of the cylindrical ΛΛ all 546. For example, the door 544 can have a relatively short height and be located where the cylindrical wall 546 meets the lower wall 548 of the burner 530.

Referring to FIG. 5F, a cross-sectional side view of an implementation of a burner 560 is shown. In this implementation, a sloped ridge 564 can be included on the lower surface of the combustion chamber 562 to help separate the accumulations 566 containing unburned primary fuel (e.g., sand. clay, or silt) from those that are spent; the

accumulations 566 tend to be heavier and therefore moving at a slower velocity than the spent non-combustible material. The ridge 564 can help to prevent exhausting unspent material that retains some primary fuel value. In other implementations, to facilitate separation of accumulations from the gases within the chamber, the lower wall of the burner can be configured in a convex or concave manner, so as to direct accumulations to a certain location within the chamber, where the} can the} be removed.

Boiler Application

Referring to FIG. 6A, a schematic representation of a prior art boiler 600 is shown.

The boiler 600 includes boiler tubes 608 through which hot gases flow to heat and boil water surrounding at least some of the boiler tubes 608; the water and/or steam is indicated by 610. In one example, the water level is approximate!} 2/3 the height of the boiler tubes and steam collects in the upper portion of the vessel; for simplicity the water and steam are both depicted as 610. A burner unit 602 is external to the firebox 606. The flame 604 initiates in the burner unit 602 and projects into the firebox 606. The flame 604 heats the firebox and the flame s exhaust gases heat the boiler tubes 608, in turn heating and boiling the water. Typically, as show n in this example, the face of the burner unit 608 is flush with the interior surface of the firebox 606 and once the flame enters the firebox 606, any sort of flame management is difficult. Additionally, the flame is typically an orange or yellow flame that produces particles of incandescent carbon in the gas exhaust stream, creating carbon deposits in the boiler tubes and flues. This carbon coating can act as an insulator and greatly reduce boiler efficiency with even a thin deposit on boiler tube surfaces.

Referring to FIG. 6B, a schematic representation of a boiler 620 using a burner 622 as described herein is shown. In this boiler 620, the burner 622 is positioned within the firebox 630 itself, rather than external to the firebox For example, the burner 622 can be configured similar to the burner 100 shown in FIGS IA and IB, burner 300 in FIGS 3 A and 3B or burner 500 in FIGS 5A and 5B The burner 622 pro\ ides both radiant heat emitting from the surfaces of the burner 622 and com ection heat pro\ided b} the exhaust gas Ad\ antageoush , because the burner 622 pro\ ides radiant heat to the firebox, the heat emitted b} the burner 622 can be determined based on the dimensions of the burner 622, and accordingly an appropπateh sized burner 622 can be selected for the particular boiler 620 The flame is substantialh. contained w ithin the burner 622 Air and fuel metering for the burner 622 can be housed outside of the firebox 630, allowing for control of the air and fuel inlet during operation An example air inlet 624 is shown, as w ell as the swirling motion of air and fuel w ithin the burner, depicted b} the arrow 626 The flow of w ater and steam is illustrated b} arrow s 632 and the boiler tubes are represented b} tubes 636

Because the burner 622 burns with a clean flame 628, i e , is a high energ} flame, and there are substantialh reduced particles included in the exhaust gas Eliminating the exhaust of incandescent carbon that creates carbon deposits on the boiler tubes impro\ es the efficiency of the boiler 620 and reduces the down-time of the boiler 620 required for cleaning and remo\ al of such carbon deposits Additionalh , excess tube heating and destruction caused b} hotspots from slag or other deposits can be a\ oided

A boiler configured w ith the burner 622 w ithin the firebox can be used in \ aπous different applications, including residential w ater heaters, commercial boilers, ship pow er plants, and the like In some implementations, the burner and all contiguous control apparatus can be mounted on a skid mount or wheeled "tra\ " that can be unattached at a boiler w all mounting flange (for example) and the entire apparatus rolled out of the firebox so a replacement burner can be rolled into place This can pro\ ide for quick and efficient replacement of a defectπ e burner or a burner requiring maintenance or replacement, thereb} minimizing dow ntime of the boiler w hen maintenance is required

Oil Sands Application

There are se\ eral techniques to reco\ er heav\ oil or bitumen from oil sands that require steam generation C\ clic Steam Stimulation (CSS) is an example of a thermal reco\ en process requiring steam A \ olume of high pressure steam is iniected through an injection w ell into an oil sands formation to heat the bitumen. The steam is generally injected at pressures above the fracture pressure of the reservoir, so a steam fracture is formed in the reservoir during injection. The reservoir may be allowed to "soak " , during which the steam condenses and releases its latent heat to the formation thus further heating the oil sands. The injection w ell is then switched to a production w ell and reservoir fluids including steam, condensed steam, mobile bitumen, and gas are produced to the surface. The production stage continues w hile economic rates of bitumen recover} are achieved. After the bitumen rate becomes too small for the process to be economic, the w ell is switched to injection and the steam injection step starts again.

Steam Assisted Gravity Drainage (SAGD) is a second example of steam assisted bitumen recovery. Typically, two horizontal w ells are drilled substantially parallel to each other in a heavy oil or bitumen reservoir, w ith one w ell positioned vertically above the second well. The upper well is the injection well and the lower well is the production w ell. Steam is injected through the upper w ell and forms a vapor phase chamber that grows within the reservoir. The injected steam reaches the edges of the depletion steam chamber and delivers latent heat to the surrounding oil sand. The oil within the oil sand is heated and. as its viscosity decreases, the oil drains under the action of gravity within and along the edges of the steam chamber toward the production well. The reservoir fluids, i.e., the heated oil and condensate, enter the production well and are motivated, either by natural pressure or by a pump, to the surface.

A variant of SAGD is the Steam and Gas Push (SAGP) process. In SAGP, steam and a non-condensable gas are co-injected into the reservoir, and the non-condensable gas forms an insulating layer at the top of the steam chamber. The well configuration is the same as the standard SAGD configuration. There are other examples of processes that use steam w ith different w ell configurations to recover heavy oil and bitumen.

The steam assisted bitumen recover} techniques described above, as w ell as others, typically use a boiler to generate the steam. A boiler configured to use the burner described herein, e.g., the burner 100 of FIGS. IA and IB, burner 300 of FIGS. 3A and 3B or burner 500 of FIGS. 5 A and 5B, can be used in these applications to efficiently generate steam. Additionally, hydrocarbon products produced by w ay of the bitumen recover} operation can be used as a primary fuel in the burner. For example, bitumen, oil sands crude or asphaltines can be used within the burner as the priman fuel Com entional burner units for boilers are not able to burn bitumen How e\ er, due to the high temperatures reached w ithin the burner and the fuel \ apoπzation resulting from the c\ clonic action within the burner wherein unburned fuel is \ apoπzed when contacting the heated interior w alls of the burner, bitumen can be used as a \ iable priman fuel Being able to use as fuel a product reco\ ered during the bitumen reco\ en operation, as compared to sa} a more expensn e option such as natural gas, can further impro\ e the efficiency of the steam generation operation

If using bitumen, that is, hea\} oil separated from the sand. cla} and/or silt of the oil sands, the bitumen can be used without am further processing Preferabh , the bitumen is pre-heated. for example, to approximate!} 315 0 C to low er the MSCOSUΛ and/or pre- mixed w ith a fluid such as w ater For example, in some implementations, the bitumen is ultrasonicalh mixed in a 70% bitumen and 30% w ater ratio before being used as the priman fuel Using one or more ultrasonic nozzles to in)ect the bitumen into the burner can also impro\ e the burner ' s performance

In some implementations, b} products from upgrading the bitumen can also be used as a priman fuel For example, coke is a solid carbonaceous material deπ\ ed from destructπ e distillation of low -ash, low -sulfur bituminous coal The coke can be ground to a pow der before using as the priman fuel

Heav\ oils can be burned as the priman fuel Some non-limiting examples include #6 fuel oil and Bunker C oil, which are oils commonh burned in boilers and pow er plants How e\ er, burning them in the burner described herein is a clean burn, and therefore ad\ antageoush has cleaner emissions and impro\ ed efficienc} In some implementations, CO 2 emissions from the burner can be routed underground

In addition to the example implementations described abo\ e, the burner can be used in an} application requiring a heat source, of which some non-limiting examples include on board a ship, an} boiler plant for industn and/or large institutions, an} heating s} stem using drocarbon fuel in a liquid or semi-solid state, e g , a home furnace or boiler The size and output can be broad ranging, for example (and w ithout limitation), from a 50,000 BTUH home boiler to a 50,000,000 BTUH SAGD steam generator In addition to steam generation, the exhaust gas from the burner can be clean and particulate- free enough to directh pow er a wide range of gas turbines

A number of embodiments of the in\ ention ha\ e been described Ne\ ertheless, it will be understood that \ aπous modifications maj be made without departing from the spirit and scope of the in\ ention Accordingly, other embodiments are within the scope of the follow ing claims