[0002] As a result of the interest in recent years to reduce the emission of polluants from burners of the type used in large furnaces and boilers, burner design has undergone substantial change. In the past, burner design improvements were aimed primarily at improving heat distribution. Increasingly stringent environmental regulations have shifted the focus of burner design to the minimization of regulated pollutants.

[0003] Oxides of nitrogen (NOx) are formed in air at high temperatures. These compounds include, but are not limited to, nitrogen oxide and nitrogen dioxide. Reduction of NOx emissions is a desired goal to decrease air pollution and meet government regulations. In recent years, a wide variety of mobile and stationary sources of NOx emissions have come under increased scrutiny and regulation.

[0004] The rate at which NOx is formed is dependent upon the following variables: (1) flame temperature, (2) residence time of the combustion gases in the high temperature zone and (3) excess oxygen supply. The rate of formation of NOx increases as flame temperature increases. However, the reaction takes time and a mixture of nitrogen and oxygen at a given temperature for a very short time may produce less NOx than the same mixture at a lower temperature, over a longer period of time.

[0005] One strategy for achieving lower NOx emission levels is to install a NOx reduction catalyst to treat the furnace exhaust stream. This strategy, known as Selective Catalytic Reduction (SCR), is very costly and, although it can be effective in meeting more stringent regulations, it represents a less desirable alternative to improvements in burner design.

[0006] Burners used in large industrial furnaces may use either liquid or gaseous fuel. Liquid fuel burners mix the fuel with steam prior to combustion to atomize the fuel to enable more complete combustion, and mix combustion air with the fuel at the zone of combustion.

[0007] Gas fired burners can be classified as either premix or raw gas, depending on the method used to combine the air and fuel. They also differ in configuration and the type of burner tip used.

[0008] Raw gas burners inject fuel directly into the air stream, such that the mixing of fuel and air occurs simultaneously with combustion.

Since airflow does not change appreciably with fuel flow, the air register settings of natural draft burners must be changed after firing rate changes.

Therefore, frequent adjustment may be necessary. In addition, many raw gas burners produce luminous flames.

[0009] Premix burners mix some or all of the fuel with some or all of the combustion air prior to combustion. Since premixing is accomplished by using the energy present in the fuel stream, airflow is largely proportional to fuel flow. As a result, therefore, less frequent adjustment is required. Premixing the fuel and air also facilitates the achievement of the desired flame characteristics. Due to these properties, premix burners are often compatible with various steam cracking furnace configurations.

[0010] Floor-fired premix burners are used in many steam crackers and steam reformers primarily because of their ability to produce a relatively uniform heat distribution profile in the tall radiant sections of these furnaces. Flames are non-luminous, permitting tube metal temperatures to be readily monitored. Therefore, a premix burner is the burner of choice for such furnaces. Premix burners can also be designed for special heat distribution profiles or flame shapes required in other types of furnaces.

[001' ! In gas fired industrial furnaces, NOx is formed by the oxidation of nitrogen drawn into the burner with the combustion air stream. The formation of NO x is widely believed to occur primarily in regions of the flame where there exist both high temperatures and an abundance of oxygen. Since ethylene furnaces are amongst the highest temperature furnaces used in the hydrocarbon processing industry, the natural tendency of burners in these furnaces is to produce high levels of NO x emissions.

[0012] One technique for reducing NOx that has become widely accepted in industry is known as combustion staging. With combustion staging, the primary flame zone is deficient in either air (fuel-rich) or fuel (fuel-lean). The balance of the air or fuel is injected into the burner in a secondary flame zone or elsewhere in the combustion chamber. As is well known, a fuel-rich or fuel-lean combustion zone is less conducive to NOx formation than an air-fuel ratio closer to stoichiometry. Combustion staging results in reducing peak temperatures in the primary flame zone and has been found to alter combustion speed in a way that reduces NOx.

Since NOx formation is exponentially dependent on gas temperature, even small reductions in peak flame temperature dramatically reduce NOx emissions. However this must be balanced with the fact that radiant heat transfer decreases with reduced flame temperature, while CO emissions, an indication of incomplete combustion, may actually increase as well.

[0013] The majority of recent low NOx burners for gas-fired industrial furnaces is based on the use of multiple fuel jets in a single burner. Such burners may employ fuel staging, flue-gas recirculation, or a combination of both. U. S. Patent Nos. 5, 098, 282 and 6,007, 325 disclose burners using a combination of fuel-staging and flue-gas recirculation. Certain burners may have as many as 8-12 fuel nozzles in a single burner. Given the practical limitations on individual burner size, the large number of fuel nozzles requires the use of very small diameter nozzles. In addition, the fuel nozzles of such burners are generally exposed to the high temperature flue-gas in the firebox.

[0014] In the high temperature environment of steam-cracking furnaces used for the manufacture of ethylene, the combination of small diameter fuel nozzles and exposure to high temperature flue gas can lead to fouling and potential plugging of the fuel jets. This not only has an adverse impact on burner performance, but also increases the cost of maintenance associated with repeated cleaning of fuel nozzles.

[0015] In the context of premix burners, the term primary air refers to the air premixed with the fuel ; secondary, and in some cases tertiary, air refers to the balance of the air required for proper combustion. In raw gas burners, primary air is the air that is more closely associated with the fuel ; secondary and tertiary air are more remotely associated with the fuel. The upper limit of flammability refers to the mixture containing the maximum fuel concentration (fuel-rich) through which a flame can propagate.

[0016] U. S. Patent No. 4,629, 413 discloses a low NOx premix burner and discusses the advantages of premix burners and methods to reduce NOx emissions. The premix burner of U. S. Patent No. 4,629, 413 lowers NOx emissions by delaying the mixing of secondary air with the flame and allowing some cooled flue gas to recirculate with the secondary air.

[0017] U. S. Patent No. 5,092, 761 discloses a method and apparatus for reducing NOx emissions from premix burners by recirculating flue gas.

Flue gas is drawn from the furnace through a pipe or pipes by the inspirating effect of fuel and combustion air passing through a venturi portion of a burner tube. The flue gas mixes with combustion air in a primary air chamber prior to combustion to dilute the concentration of 02 in the combustion air, which lowers flame temperature and thereby reduces NOx emissions. The flue gas recirculating system may be retrofitted into existing premix burners or may be incorporated in new low NOx burners.

[0018] An advantage of the staged-air pre-mix burners disclosed in U. S. Patent Nos. 4,629, 413 and 5,092, 761 relates to their use of a single fuel nozzle. This permits the size of the fuel nozzle to be the maximum possible for a given burner firing duty. In addition, since the fuel nozzle is located at the inlet to the venturi, it is not exposed directly to either the high temperature flue-gas or the radiant heat of the firebox. For these reasons the problems of fuel nozzle fouling are minimized, providing a significant advantage for the staged-air pre-mix burner in ethylene furnace service.

[0019] An additional challenge to the designer of low NOx burners is to maintain adequate flame stability. The very techniques used to minimize NOx emissions reduce flame temperature and flame speed, and generally lead to less stable flames that are more prone to"lift-off.""Lift- off"is a term used to describe a flame where the point of combustion has left the burner tip. In extreme cases, lift-off can lead to instances of flame- out; where combustion at the burner is extinguished. Such a condition is highly undesirable as it can potentially lead to an accumulation of an air/fuel mixture in the firebox.

[0020]} From the standpoint of NOx production, a drawback with respect to the presence of localized sources of high NOx production has been discovered which is associated with the burner tip design of the burner of U. S. Patent No. 5,092, 761. One drawback relates to the inability to precisely distribute air flow adjacent to the burner tip which can result in localized sources of high NOx production.

[0021] Despite these advances in the art, a need exists for a highly efficient burner design for industrial use to meet increasingly stringent NOx emission regulations, which minimizes localized sources of high NOx production.

[0022] Therefore, what is needed is a burner for the combustion of fuel and air wherein localized sources of high NOx production are substantially reduced, yielding further reductions in NOx emissions.

The present invention is directed to an improved burner such as those found in steam cracking. In one embodiment, the burner includes : (a) a burner tube having a longitudinal axis and having a downstream end and an upstream end for receiving fuel and air, flue gas or mixtures thereof ; (b) a fuel orifice located adjacent the upstream end of said burner tube, for introducing fuel into said burner tube ; (c) a burner tip mounted on the downstream end of said burner tube and adjacent a first opening in the furnace, said burner tip having a plurality of main ports substantially aligned with said longitudinal axis of the burner tube, and a plurality of peripherally arranged side ports; and (d) a peripheral tile which peripherally surrounds said burner tip, said peripheral tile providing at least one gap between an outer periphery of said burner tip and said peripheral tile, said at least one gap effective for providing a portion of the air for combustion [0023] wherein the quantity of fuel discharged during combustion from said peripherally arranged side ports does not exceed 15% of the total fuel gas combusted.

[0024] The invention is further explained in the description that follows with reference to the drawings illustrating, by way of non-limiting examples, various embodiments of the invention wherein: FIG. 1 illustrates an elevation partly in section of an embodiment of the burner of the present invention; FIG. 2 is an elevation partly in section taken along line 2--2 of FIG.

1; FIG. 3 is a plan view taken along line 3--3 of FIG. 1; FIG. 4 is a plan view taken along line 4--4 of FIG. 1; FIG. 5 is an elevation partly in section of another embodiment of the burner of the present invention; FIG. 6 is an elevation partly in section taken along line 6--6 of FIG.

1; FIG. 7 is a plan view taken along line 7-7 of FIG. 5; FIG. 8 is an elevation partly in section of another embodiment of the burner of the present invention; FIG. 9 is an elevation partly in section taken along line 9--9 of FIG.

7; FIG. 10 is a plan view taken along line 10--10 of FIG. 8; FIG. 11 is a plan view showing a burner tip according to another embodiment of the present invention; FIG. 12A is an enlarged view of one embodiment of a burner tip seal ; FIG. 12B is an enlarged view of another embodiment of a burner tip seal ; FIG. 12C is an enlarged view of yet another embodiment of a burner tip seal ; FIG. 13 illustrates an embodiment of a seal means for sealing in the region of the pilot chamber; FIG. 14A is a perspective view of a conventional burner tip; FIG. 14B is a perspective view of an embodiment of a burner tip; FIG. 15 is an elevation partly in section of the embodiment of a flat- flame burner; FIG. 16 is an elevation partly in section of the embodiment of a flat- flame burner of FIG. 15 taken along line 16--16 of FIG. 15; FIG 17A is a top view of one embodiment of a burner tip seal for use in a burner of the type depicted in FIGS. 8-10; FIG. 17B is a top view of another embodiment of a burner tip seal for use in a flat-flame burner; and FIG. 18 is a top view of another embodiment of a burner tip for use in a flat-flame burner.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS [0025] Reference is now made to the embodiments illustrated in FIGS. 1 through 18, wherein like numerals are used to designate like parts throughout.

[0026] Although the present invention is described in terms of a burner for use in connection with a furnace or an industrial furnace, it will be apparent to one of skill in the art that the teachings of the present invention also have applicability to other process components such as, for example, boilers. Thus, the term furnace herein shall be understood to mean furnaces, boilers and other applicable process components.

[0027] Referring now to FIGS. 1 through 4, a burner 10 includes a freestanding burner tube 12 located in a well in a furnace floor 14. Burner tube 12 includes an upstream end 16, a downstream end 18 and a venturi portion 19. Burner tip 20 is located at downstream end 18 and is surrounded by a peripheral tile 22. Fuel orifice 11, which may be located within a gas spud 24, is located at upstream end 16 and introduces fuel into burner tube 12. Fresh or ambient air is introduced into primary air chamber 26 through adjustable damper 28 to mix with the fuel at upstream end 16 of burner tube 12. Combustion occurs downstream of burner tip 20.

[0028] Referring still to FIGS. 1 through 4, burner tip 20 has an upper end 66, which when installed, faces the furnace box, and a lower end 68 adapted for mating with the burner tube 12. Lower end 68 of burner tip 20 may be mated to burner tube 12 by welding, swaging or threaded engagement, with welding or threaded engagement being particularly preferred. In operation, side-ports 62 direct a fraction of the fuel across the face of peripheral tile 22, while main ports 64 direct the major portion of the fuel into the furnace. In a conventional burner tip, side ports are provided about the entire periphery of the outer edge of the burner tip.

[0029] A plurality of air ports 30 originates in secondary air chamber 32 and pass through furnace floor 14 into the furnace. Fresh air enters secondary air chamber 32 through adjustable dampers 34 and passes through air ports 30 into the furnace to provide secondary or staged combustion, as described in U. S. Patent No. 4,629, 413.

[0030] In order to recirculate flue gas from the furnace to the primary air chamber, ducts or pipes 36,38 extend from openings 40,42, respectively, in the floor of the furnace to openings 44,46, respectively, in burner plenum 48. Flue gas containing, for example, 0 to 15% 02 is drawn through pipes 36,38 with 5 to 15% Os preferred, 2 to 10% 02 more preferred and 2 to about 5% Os particularly preferred, by the inspirating effect of fuel passing through venturi portion 19 of burner tube 12. In this manner, the primary air and flue gas are mixed in primary air chamber 26, which is prior to the zone of combustion. Therefore, the amount of inert material mixed with the fuel is raised, thereby reducing the flame temperature and, as a result, reducing NOx emissions. Closing or partially closing damper 28 restricts the amount of fresh air that can be drawn into the primary air chamber 26 and thereby provides the vacuum necessary to draw flue gas from the furnace floor 14.

[0031] Unmixed low temperature ambient air, having entered secondary air chamber 32 through dampers 34 and having passed through air ports 30 into the furnace, is also drawn through pipes 36,38 into the primary air chamber by the inspirating effect of the fuel passing through venturi portion 19. The ambient air may be fresh air as discussed above. The mixing of the ambient air with the flue gas lowers the temperature of the hot flue gas flowing through pipes 36,38 and thereby substantially increases the life of the pipes and permits use of this type of burner to reduce NOx emission in high temperature cracking furnaces having flue gas temperature above 1038°C (1900°F) in the radiant section of the furnace.

[0032] It is preferred that a mixture of from 20% to 80% flue gas and from 20% to 80% ambient air should be drawn through pipes 36, 38. It is particularly preferred that a mixture of 50% flue gas and 50% ambient air be employed. The desired proportions of flue gas and ambient air may be achieved by proper sizing, placement and/or design of pipes 36,38 in relation to air ports 30, as those skilled in the art will readily recognize.

That is, the geometry of the air ports, including but not limited to their distance from the burner tube, the number of air ports, and the size of the air ports, may be varied to obtain the desired percentages of flue gas and ambient air.

[0033] As is shown in FIGS. 7,11, 14A and 14B, a very small gap exists between the burner tip 20 and the peripheral tile 22. By properly engineering this gap, the bulk of the secondary staged air is forced to enter the furnace through staged air ports 30 located some distance from the primary combustion zone, which is located immediately on the furnace side of the burner tip 20.

[0034l It has been discovered through testing that increasing the available flow area of the gap between the burner tip 20 and the peripheral burner tile 22 raises the overall NOx emissions produced by the burner, although it tends to also benefit flame stability. In view of its impact on NOX emissions, each gap between the burner tip 20 and the peripheral tile 22 must be correctly sized to maintain stability and minimize NOx.

[0035] To optimize burner performance for low NOx emissions, the distance between the burner tip 20 and peripheral tile 22 must be held to a tight dimensional tolerance to ensure good air distribution around burner tip 20 and to minimize or significantly reduce unwanted air flow into the region. This unwanted air flow can cause the flames emanating from the side ports to be closer to stoichiometric conditions, tending to raise flame temperature and NOX levels.

[0036] Referring now to FIGS. 4,10, 14B and 17A as may be appreciated by those skilled in the art, the outer diameter of the burner tip 20 and the air flow notches 72 can be manufactured to relatively tight tolerances through investment casting or machining. However, the peripheral tile 22 is more difficult to manufacture to the same tolerances, creating an unwanted gap between the outer diameter of the burner tip 20 and the peripheral tile 22. Typically, a peripheral tile is poured into a mold using a castable refractory material. Compounding the problem of producing peripheral burner tiles to tight tolerances is the amount of shrinkage that the tiles experience when dried and fired. The amount of shrinkage varies according to material, temperature, and geometry, causing additional uncertainties in the final manufactured tolerances.

These factors contribute to the difficulty in consistently manufacturing a tile to a specified diameter, which can lead to a tile that is too small in diameter or, more commonly, one that is too large in diameter.

[0037] While a potential solution is to manufacture the peripheral tile burner tip hole to a tighter tolerance, this requires that the peripheral tile's hole be machined, rather than cast. However, machining a hole in a conventional peripheral tile is difficult, time consuming and costly. Further, even if the tolerances are small during manufacturing, problems such as cracking of the ceramic material can occur due to differential thermal expansion between the metallic burner tip and the ceramic tile.

[0038] Referring to FIGS. 12 A-C and 17A, to establish a uniform dimension between the burner tip 20 and the peripheral burner tile 22 for the air gaps 70, a burner tip band 85, which may be formed of steel or other metal or metal composite capable of withstanding the harsh environment of an industrial burner, is attached to the outer periphery of burner tip 20, by tack welding or other suitable means. Advantageously, a compressible high temperature material 87 is optionally employed in the unwanted gap between the burner tip band 85 and the peripheral tile 22 to further reduce or eliminate the gap. Burner tip band 85 may further include a peripheral indentation 81 (see FIG. 12A) or peripheral indentation 83 (see FIG. 12C), respectively, for seating said compressible high temperature material. An advantage of this novel design is that the peripheral tile hole size can vary significantly, while the compressible material can be adjusted for this variance in order to maintain the seal between the burner tip 20 and peripheral tile 22. By using the burner tip designs of the present invention, the air gap between the burner tip and peripheral tile can be maintained to exacting tolerances, essentially eliminating unwanted air leakage.

[0039] As may be appreciated, compressible material 87 should be rated for high temperature service since it is very close to the burner side port flames. A material that expands when heated is very useful as compressible material 87 because it makes the initial installation much easier. Examples of suitable materials include, but are not limited to, Triple T by Thermal Ceramics and Organically Bound After (OBM After) distributed by Thermal Ceramics of Atlanta, GA, a division of Morgan Crucible. It was found that OBM Maftec is preferable since it held together better after being exposed to high temperatures. OBM Maftec is produced from high quality mullite fiber. This material is known to possess low thermal conductivity and heat storage and is resistant to thermal shock and chemical attack. It additionally is highly flexible, has a maximum temperature rating of 1593 °C (2900 °F) and a continuous use limit of up to 1482 °C (2700 °F), making it ideal for this application. While the Triple T material expands more than the After, it was found to flake apart more easily after heating.

[0040] Referring now to FIGS. 1,3, 5 and 9, a sight and lighting port 50 is provided in the burner plenum 48, both to allow inspection of the interior of the burner assembly, and to provide access for lighting of the burner through lighting chamber 60 (see FIGS. 4,11 and 14B). As shown, the sight and lighting port 50 is aligned with lighting chamber 60, which is adjacent to the first opening in the furnace. Lighting chamber 60 is located at a distance from burner tip 20 effective for burner light off. A lighting torch or igniter (not shown) of the type disclosed in U. S. Patent 5,092, 761 has utility in the start-up of the burner of the present invention, as those skilled in the art will readily understand. To operate the burner of the present invention, the torch or igniter is inserted through light-off tube 50 into the lighting chamber 60, which is adjacent burner tip 20, to light the burner.

[0041] In another embodiment of the present invention as illustrated by FIGS. 1 through 7, a burner 10 includes a freestanding burner tube 12 located in a well in a furnace floor 14. Burner tube 12 includes an upstream end 16, a downstream end 18 and a venturi portion 19. Burner tip 20 is located at downstream end 18 and is surrounded by a peripheral tile 22. A fuel orifice 11, which may be located within a gas spud 24, is located at upstream end 16 and introduces fuel into burner tube 12. Fresh or ambient air is introduced into primary air chamber 26 through adjustable damper 28 to mix with the fuel at upstream end 16 of burner tube 12.

Combustion occurs downstream of burner tip 20.

[0042] Referring to FIGS. 1 through 7, burner tip 20 has an upper end 66, which when installed, faces the furnace box, and a lower end 68 adapted for mating with the burner tube 12. Lower end 68 of burner tip 20 may be mated to burner tube 12 by welding, swaging or threaded engagement, with welding or threaded engagement being particularly preferred. In operation, side-ports 62 direct a fraction of the fuel across the face of peripheral tile 22, while main ports 64 direct the major portion of the fuel into the furnace.

[0043] A plurality of air ports 30 originates in secondary air chamber 32 and pass through furnace floor 14 into the furnace. Fresh air enters secondary air chamber 32 through adjustable dampers 34 and passes through air ports 30 into the furnace to provide secondary or staged combustion, as described in U. S. Patent No. 4,629, 413.

[0044] In order to recirculate flue gas from the furnace to the primary air chamber, ducts or pipes 36,38 extend from openings 40,42, respectively, in the floor of the furnace to openings 44,46, respectively, in burner plenum 48. Flue gas containing, for example, 0 to 15% 02 is drawn through pipes 36,38 with 5 to 15% °2 preferred, 2 to about 10% 02 more preferred and 2 to 5% Os particularly preferred, by the inspirating effect of fuel passing through venturi portion 19 of burner tube 12. In this manner, the primary air and flue gas are mixed in primary air chamber 26, which is prior to the zone of combustion. Therefore, the amount of inert material mixed with the fuel is raised, thereby reducing the flame temperature, and as a result, reducing NOx emissions. Closing or partially closing damper 28 restricts the amount of fresh air that can be drawn into the primary air chamber 26 and thereby provides the vacuum necessary to draw flue gas from the furnace floor 14.

[0045] Unmixed low temperature ambient air, having entered secondary air chamber 32 through dampers 34 and having passed through air ports 30 into the furnace, is also drawn through pipes 36,38 into the primary air chamber by the inspirating effect of the fuel passing through venturi portion 19. The ambient air may be fresh air as discussed above. The mixing of the ambient air with the flue gas lowers the temperature of the hot flue gas flowing through pipes 36,38 and thereby substantially increases the life of the pipes and permits use of this type of burner to reduce NOx emission in high temperature cracking furnaces having flue gas temperature above 1038 °C (1900 °F) in the radiant section of the furnace.

[0046] It is preferred that a mixture of from 20% to 80% flue gas and from 20% to 80% ambient air should be drawn through pipes 36, 38. It is particularly preferred that a mixture of 50% flue gas and 50% ambient air be employed. The desired proportions of flue gas and ambient air may be achieved by proper sizing, placement and/or design of pipes 36,38 in relation to air ports 30, as those skilled in the art will readily recognize.

That is, the geometry of the air ports, including but not limited to their distance from the burner tube, the number of air ports, and the size of the air ports, may be varied to obtain the desired percentages of flue gas and ambient air.

[0047] As is shown in FIGS. 5 and 7, and in more detail in FIGS 14A and 14B, a very small gap exists between the burner tip 20 and the peripheral tile 22. By keeping this gap small, the bulk of the secondary staged air is forced to enter the furnace through staged air ports 30 located some distance from the primary combustion zone, which is located immediately on the furnace side of the burner tip 20. This gap may be a single peripheral gap having a substantially uniform gap 71, as shown in FIG. 14A, or alternatively, comprise a gap 69 of periodically varying width, as shown in FIG. 14B.

[0048] It has been discovered through testing that increasing the gap between the burner tip 20 and the peripheral tile 22 raises overall the NOx emissions produced by the burner, although it tends to also benefit flame stability. In view of its impact on NOx emissions, the gap between the burner tip 20 and the peripheral tile 22 must be correctly sized.

[0049] A sight and lighting port 50 provides access to the interior of secondary air chamber 32 for a lighting torch or igniter (not shown). As shown, the sight and lighting port 50 is aligned with lighting chamber 60, which is adjacent to the first opening in the furnace. Lighting chamber 60 is located at a distance from burner tip 20 effective for burner light off. A lighting torch or igniter (not shown) of the type disclosed in U. S. Patent 5,092, 761 has utility in the start-up of the burner of the present invention, as those skilled in the art will readily understand. To operate the burner of the present invention, the torch or igniter is inserted through light-off tube 50 into the lighting chamber 60, which is adjacent burner tip 20, to light the burner [0050] The burner tip of the present invention may also be used in a low NOX burner design of the type illustrated in FIGS. 8,9 and 10, wherein like reference numbers indicate like parts. As with the embodiment of FIGS. 1 through 4, a burner 10 includes a freestanding burner tube 12 located in a well in a furnace floor 14. Burner tube 12 includes an upstream end 16, a downstream end 18 and a venturi portion 19. Burner tip 20 is located at downstream end 18 and is surrounded by a peripheral tile 22. Gas spud 24 is located at upstream end 16 and introduces fuel into burner tube 12. Fresh or ambient air is introduced into primary air chamber 26 through adjustable damper 28 to mix with the fuel at upstream end 16 of burner tube 12. Combustion of the fuel occurs downstream of burner tip 20.

[0051] As with the burner designs illustrated in FIGS. 1 through 7, the burner of FIGS. 8 through 10 has a burner tip 20, which has an upper end 66, which when installed, faces the furnace box, and a lower end 68 adapted for mating with the burner tube 12. As previously described, lower end 68 of burner tip 20 may be mated to burner tube 12 by welding, swaging or threaded engagement, with welding or threaded engagement being particularly preferred. In operation, side-ports 62 direct a fraction of the fuel across the face of peripheral tile 22, while main ports 64 direct the major portion of the fuel into the furnace.

[0052] A plurality of air ports 30 originates in secondary air chamber 32 and pass through furnace floor 14 into the furnace. Fresh air enters secondary air chamber 32 through adjustable dampers 34 and passes through staged air ports 30 into the furnace to provide secondary or staged combustion.

[0053] In order to recirculate flue gas from the furnace to the primary air chamber, a flue gas recirculation passageway 76 is formed in furnace floor 14 and extends to primary air chamber 26, so that flue gas is mixed with fresh air drawn into the primary air chamber from opening 80. Flue gas containing, for example, 6-10% °2 is drawn through passageway 76 by the inspirating effect of fuel passing through venturi portion 19 of burner tube 12. As with the embodiments of FIGS. 1 through 6, the primary air and flue gas are mixed in primary air chamber 26, which is prior to the zone of combustion. Closing or partially closing damper 28 restricts the amount of fresh air that can be drawn into the primary air chamber 26 and thereby provides the vacuum necessary to draw flue gas from the furnace floor 14.

[0054] As with the embodiments of FIGS. 1 through 7, a mixture of approximately 50% flue gas and approximately 50% ambient air is drawn through flue gas recirculation passageway 76. The desired proportions of flue gas and ambient air may be achieved by proper sizing, placement and/or design of flue gas recirculation passageway 76 and air ports 30; that is, the geometry and location of the air ports may be varied to obtain the desired percentages of flue gas and ambient air.

[0055] Sight and lighting port 50 provides access to the interior of secondary air chamber 32 for a lighting torch or igniter (not shown). As with the embodiments of present invention depicted in FIGS. 1 through 6, a lighting torch or igniter of the type disclosed in U. S. Patent 5,092, 761 has utility in this embodiment of the present invention. Sight and lighting port 50 allows inspection of the interior of the burner assembly and access for lighting of the pilot 86. Pilot 86 is located at a distance from burner tip 20 effective for burner light-off. As shown in FIG. 8, a tube 84 provides access to the interior of secondary air chamber 32 for pilot 86.

[0056] Still referring to FIGS. 8 through 10, a fuel orifice 11, which may be located within gas spud 24, discharges fuel into burner tube 12, where it mixes with primary air, recirculated flue-gas or a mixture of primary air and recirculated flue-gas. The mixture of fuel and air, flue gas or mixtures thereof then discharges from burner tip 20. The mixture in the venturi portion 19 of burner tube 12 is maintained below the fuel-rich flammability limit ; i. e. there is insufficient air in the venturi to support combustion. Staged, secondary air is added to provide the remainder of the air required for combustion. The majority of the staged air is added a finite distance away from the burner tip 20 through staged air ports 30.

However, as with the design of FIGS. 1-4, a portion of the staged, secondary air passes between the burner tip 20 and the peripheral tile 22 through a plurality of air gaps 70 and is immediately available to the fuel exiting the side ports 62 of burner tip 20. Side-ports 62 direct a fraction of the fuel across the face of the peripheral tile 22, while main ports 64 of burner tip 20, direct the major portion of the fuel into the furnace.

[0057] As may be envisioned, two combustion zones are established.

A small combustion zone is established across the face of the peripheral tile 22, emanating from the fuel combusted in the region of the side-ports 62, while a much larger combustion zone is established projecting into the furnace firebox, emanating from the fuel combusted from the main ports 64. In operation, the larger combustion zone represents an approximately cylindrical face of combustion extending up from the burner, where the staged air flowing primarily from air ports 30 meets the fuel-rich mixture exiting from the burner tip main ports 64.

[0058] Analysis of burner performance has shown that the combustion zone adjacent to the side ports 62 and peripheral tile 22 is important in assuring flame stability. To provide adequate flame stability, the air/fuel mixture in this zone, which comprises the air/fuel mixture leaving the side ports 62 of burner tip 20, plus the air passing between the burner tip 20 and the peripheral tile 22 through a plurality of air gaps 70, must be above the fuel-rich flammability limit.

[0059] While a mixture above the fuel-rich flammability limit in the combustion zone adjacent to the side ports 62 and peripheral tile 22 assures good burner stability, combustion in this zone has been found to generate relatively high NOx levels compared to the larger combustion zone. To achieve lower NOx levels it is important that the air flow between burner tip 20 and the peripheral tile 22 be such that combustion takes place within this zone with a mixture sufficiently above the fuel-rich flammability limit to assure good burner stability, but without the high oxygen concentrations that lead to high NOx emissions.

[0060] As is shown in FIGS. 14A and 14B, a very small gap exists between the burner tip 20 and the peripheral tile 22. As previously described, by keeping this gap small, the bulk of the secondary staged air is forced to enter the furnace through staged air ports 30 located some distance from the primary combustion zone, which is located immediately on the furnace side of the burner tip 20. While this gap may be a substantially peripheral gap, it preferably comprises a series of spaced gaps 70 peripherally arranged, as shown in FIGS. 8-10, and in more detail in FIG. 17 A.

[0061] The previously described configurations depicted in FIGS. 12 A-C and 17A may advantageously be employed in the burner design of FIGS. 8-10. As with the burner of FIGS. 1-4, to establish a uniform dimension between the burner tip 20 and the peripheral tile 22 for the air gaps 70, a burner tip band 85, may be formed of steel or other metal or metallic-composite capable of withstanding the harsh environment of an industrial burner and attached to the outer periphery of burner tip 20, by tack welding or other suitable means. A compressible high temperature material 87 is optionally employed in the unwanted gap between the burner tip band 85 and the peripheral tile 22 to further reduce or eliminate the gap. Compressible material 87 may be selected from any of the materials previously described or their equivalents.

[0062] Referring now to FIG. 13, a similar benefit may be obtained in the region of pilot 86, adjacent to the first opening in the furnace. It has been observed that significant leakage occurs in typical designs due to gaps existing around the pilot shield 88. To remedy this, a compressible high temperature material 87 is installed around the pilot shield 88, and/or pilot riser 89 to eliminate the unwanted gap between the burner tip band 85 and the peripheral tile 22, as shown in FIG. 13. For example, it has been found that a 2.54 cm (1.0 in) wide by 5.0 mm (0.1969 in) thick strip of OBM Maftec works particularly well to seal gaps existing around the pilot shield 88.

[0063] As shown in FIGS. 5-7,11 and, in particular, to 14B, another embodiment of the present invention may include a burner tip 20, which has an upper end 66, which when installed, faces the furnace box, and a lower end 68 (see FIG. 9) adapted for mating with the burner tube 12. As previously described, lower end 68 of burner tip 20 may be mated to burner tube 12 by welding, swaging or threaded engagement, with welding or threaded engagement being particularly preferred. In operation, side- ports 62 direct a fraction of the fuel across the face of peripheral tile 22, while main ports 64 direct the major portion of the fuel into the furnace.

[0064] Two combustion zones are established. A small combustion zone across the face of the peripheral tile 22, emanating from the fuel combusted in the region of the side-ports 62, while a much larger combustion zone is established projecting into the furnace firebox, emanating from the fuel combusted from the main ports 64. Analysis of burner performance has shown that the combustion zone adjacent to the side ports 62 and peripheral tile 22 is important in assuring flame stability.

To provide adequate flame stability, the air/fuel mixture in this zone, which comprises the air/fuel mixture leaving the side ports 62 of burner tip 20, plus the air passing between the burner tip 20 and the peripheral tile 22, must be above the fuel-rich flammability limit.

[0065] While a mixture above the fuel-rich flammability limit in the combustion zone adjacent to the side ports 62 and peripheral tile 22 assures good burner stability, combustion in this zone has been found to generate relatively high NOx levels compared to the larger combustion zone. It has been discovered that overall NOx emissions may be reduced by minimizing the proportion of fuel that is combusted in this smaller combustion zone. More particularly, in a staged-air, pre-mix burner employing integral flue-gas recirculation, when the quantity of fuel discharged into the combustion zone adjacent to side ports 62 and peripheral tile 22 does not exceed 15% of the total fuel fired in the burner, lower overall NOx emissions are expected. This is achieved by further assuring that the air flow between burner tip 20 and the peripheral tile 22 is such that combustion takes place within this zone with a mixture sufficiently above the fuel-rich flammability limit to assure good burner stability, but without the high oxygen concentrations that lead to high NOx emissions.

[0066] As those skilled in the art recognize, the reduction in the number of side ports 62 necessary to achieve the objects of the present invention is dependent upon a number of factors including the properties of the fuel, itself, the dynamics of fluid flow and the kinetics of combustion.

While the burner tips of the present invention present designs having about a 53% reduction in the number of side ports 62, it would be expected that reductions in the number of side ports 62 ranging from about 25% to about 75% could be effective as well, so long as each side port and the burner-tip-to-peripheral-tile gap is appropriately sized.

[0067] Similar benefits can be achieved in flat-flame burners, as will now be described by reference to FIGS. 15,16, 17B and 18. A burner 110 includes a freestanding burner tube 112 located in a well in a furnace floor 114. Burner tube 112 includes an upstream end 116, a downstream end 118 and a venturi portion 119. Burner tip 120 is located at downstream end 118 and is surrounded by a peripheral tile 122. A fuel orifice 111, which may be located within gas spud 124, is located at upstream end 116 and introduces fuel into burner tube 112. Fresh or ambient air is introduced into primary air chamber 126 to mix with the fuel at upstream end 116 of burner tube 112. Combustion of the fuel occurs downstream of burner tip 120. Fresh or ambient secondary air enters secondary chamber 132 through dampers 134. $ [0068] In order to recirculate flue gas from the furnace to the primary air chamber, a flue gas recirculation passageway 176 is formed in furnace floor 114 and extends to primary air chamber 126, so that flue gas is mixed with fresh air drawn into the primary air chamber from opening 180 through dampers 128. Flue gas containing, for example, 0 to 15% 02 is drawn through passageway 176 by the inspirating effect of fuel passing through venturi portion 119 of burner tube 112. Primary air and flue gas are mixed in primary air chamber 126, which is prior to the zone of combustion.

[0069] As is shown in FIG. 18, a very small gap exists between the burner tip 120 and the peripheral tile 122. By correctly sizing this gap, the bulk of the secondary staged air is forced to enter the furnace through staged air ports (not shown) located some distance from the primary combustion zone, which is located immediately on the furnace side of the burner tip 120. This gap may be a peripheral gap 171 as shown in FIG.

18, or alternatively, comprise a series of spaced gaps 170 peripherally arranged, as shown in FIG. 17B.

[0070] As previously noted, it has been discovered through testing that increasing the flow area between the burner tip 120 and the peripheral tile 122 raises overall the NOx emissions produced by the burner, although it tends to also benefit flame stability. In view of its impact on NOx emissions, the flow area between the burner tip 120 and the peripheral tile 122 must be correctly sized.

[0071] Referring to FIG. 18, the outer diameter of the burner tip 120 and the air flow notches 172 can be manufactured to relatively tight tolerances through investment casting or machining. However, the peripheral tile 122 is more difficult to manufacture to the same tolerances, creating an unwanted gap between the outer diameter of the burner tip 120 and the peripheral tile 122.

[0072] Referring still to FIGS. 17B and 18, side-ports 162 direct a fraction of the fuel across the face of the peripheral tile 122, while main ports 164, direct the major portion of the fuel into the furnace. Two combustion zones are established. A small combustion zone is established across the face of the peripheral tile 122, emanating from the fuel combusted in the region of the side-ports 162, while a much larger combustion zone is established projecting into the furnace firebox, emanating from the fuel combusted from the main ports 164. The combustion zone adjacent to the side ports 162 and peripheral tile 122 is important in assuring flame stability. To provide adequate flame stability, the air/fuel mixture in this zone, which comprises the air/fuel mixture leaving the side ports 162 of burner tip 120, plus the air passing between the burner tip 120 and the peripheral tile 122, must be above the fuel-rich flammability limit.

[0073] While a mixture above the fuel-rich flammability limit in the combustion zone adjacent to the side ports 162 and peripheral tile 122 assures good burner stability, combustion in this zone will generate relatively high Nos levels compared to the larger combustion zone.

Overall NOX emissions may be reduced by minimizing the proportion of fuel that is combusted in this smaller combustion zone. This is achieved by assuring that the air flow between burner tip 120 and the peripheral tile 122 is such that combustion takes place within this zone with a mixture sufficiently above the fuel-rich flammability limit to assure good burner stability, but without the high oxygen concentrations that lead to high NOx emissions.

[0074] Referring now to FIG. 17 B, to establish a uniform dimension between the burner tip 120 and the peripheral burner tile 122 for the air gaps 170, a burner tip band 185, may be formed of steel or other metal or metallic-composite capable of withstanding the harsh environment of an industrial burner and attached to the outer periphery of burner tip 120, by tack welding or other suitable means. A compressible high temperature material 187 is optionally employed in the unwanted gap between the burner tip band 185 and the peripheral tile 122 to further reduce or eliminate the gap. Compressible material 187 may be selected from any of the materials previously described or their equivalents.

[0075] A flat-flame burner arrangement may also be used in connection with the novel burner tip, as will now be described by reference to FIGS. 15,16, 17B and 18. Burner 110 includes a freestanding burner tube 112 located in a well in a furnace floor 114. Burner tube 112 includes an upstream end 116, a downstream end 118 and a venturi portion 119.

Burner tip 120 is located at downstream end 118 and is surrounded by a peripheral tile 122. A fuel orifice 111, which may be located within a gas spud 124, is located at upstream end 116 and introduces fuel into burner tube 112. Fresh or ambient air is introduced into primary air chamber 126 to mix with the fuel at upstream end 116 of burner tube 112. Combustion of the fuel and fresh air occurs downstream of burner tip 120. Fresh secondary air enters secondary chamber 132 through dampers 134.

[0076] In order to recirculate flue gas from the furnace to the primary air chamber, a flue gas recirculation passageway 176 is formed in furnace floor 114 and extends to primary air chamber 126, so that flue gas is mixed with fresh air drawn into the primary air chamber from opening 180 through dampers 128. Flue gas containing, for example, 0 to 15% Os is drawn through passageway 176 by the inspirating effect of fuel passing through venturi portion 119 of burner tube 112. Primary air and flue gas are mixed in primary air chamber 126, which is prior to the zone of combustion.

[0077] As is shown in FIG. 18 and according to another embodiment of the present invention, a very small gap exists between the burner tip 120 and the peripheral tile 122. By keeping this gap small, the bulk of the secondary staged air is forced to enter the furnace through staged air ports (not shown) located some distance from the primary combustion zone, which is located immediately on the furnace side of the burner tip 120. This gap may be peripheral gap 171 as shown in FIG. 18, or alternatively, comprise a series of spaced gaps 170 peripherally arranged, as shown in FIG. 17B.

[0078] As previously noted, it has been discovered through testing that increasing the flow area between the burner tip 120 and the peripheral tile 122 raises overall the NOx emissions produced by the burner, although it tends to also benefit flame stability. In view of its impact on NOx emissions, the flow area between the burner tip 120 and the peripheral tile 122 must be correctly sized..

[0079] In operation, a fuel orifice 111, which may be located within a gas spud 124, discharges fuel into burner tube 112, where it mixes with primary air and recirculated flue-gas. The mixture of fuel, recirculated flue- gas and primary air then discharges from burner tip 120. The mixture in the venturi portion 119 of burner tube 112 is maintained below the fuel-rich flammability limit ; i. e. there is insufficient air in the venturi to support combustion. Staged, secondary air is added to provide the remainder of the air required for combustion. The majority of the staged air is added a finite distance away from the burner tip 120 through staged air ports (not shown). However, a portion of the staged, secondary air passes between the burner tip 120 and the peripheral tile 122 and is immediately available to the fuel exiting the side ports 162. As indicated, side-ports 162 direct a fraction of the fuel across the face of the peripheral tile 122, while main ports 164, direct the major portion of the fuel into the furnace.

[0080] Again, two combustion zones are established. A small combustion zone across the face of the peripheral tile 122, emanating from the fuel combusted in the region of the side-ports 162, while a much larger combustion zone is established projecting into the furnace firebox, emanating from the fuel combusted from the main ports 164. Analysis of burner performance has shown that the combustion zone adjacent to the side ports 162 and peripheral tile 122 is important in assuring flame stability. To provide adequate flame stability, the air/fuel mixture in this zone, which comprises the air/fuel mixture leaving the side ports 162 of burner tip 120, plus the air passing between the burner tip 120 and the peripheral tile 122, must be above the fuel-rich flammability limit.

[0081] While a mixture above the fuel-rich flammability limit in the combustion zone adjacent to the side ports 162 and peripheral tile 122 assures good burner stability, combustion in this zone has been found to generate relatively high NOx levels compared to the larger combustion zone. It has been discovered that overall NOx emissions may be reduced by minimizing the proportion of fuel that is combusted in this smaller combustion zone. More particularly, in a staged-air, pre-mix burner employing integral flue-gas recirculation, when the quantity of fuel discharged into the combustion zone adjacent to side ports 162 and peripheral tile 122 does not exceed 15% of the total fuel fired in the burner, lower overall NOx emissions are expected. This is achieved by further assuring that the air flow between burner tip 120 and the peripheral tile 122 is such that combustion takes place within this zone with a mixture sufficiently above the fuel-rich flammability limit to assure good burner stability, but without the high oxygen concentrations that lead to high NOx emissions.

[0082] As those skilled in the art recognize, the reduction in the number of side ports necessary to achieve the objects of the present invention is dependent upon a number of factors including the properties of the fuel, itself, the dynamics of fluid flow and the kinetics of combustion.

While the burner tips of the present invention present designs having about a 53% reduction in the number of side ports, it would be expected that reductions in the number of side ports ranging from about 25% to about 75% could be effective as well, so long as each side port and the burner-tip-to-peripheral-tile gap is appropriately sized.

[0083] In the burner tip designs of the present invention, preferably the dimensions of the burner-tip-to-peripheral-tile gap are such that the total air available to the fuel gas exiting the side ports (i. e. the sum of air exiting the side ports with the fuel gas, plus the air supplied through gap), is between 5 to 15-percentage points above the Fuel Rich Flammability Limit for the fuel being used. For example, if the fuel being used has a Fuel Rich Flammability Limit of 55% of the air required for stoichiometric combustion, the air available to the fuel gas exiting the side ports should represent 60-70% of the air required for stoichiometric combustion.

Unlike prior designs, use of the burner tip seal of the present invention serves to substantially minimize localized sources of high NOx emissions in the region near the burner tip.

Examples [0084] To assess the benefits of the present invention, computational fluid dynamics, CFD, were used to evaluate the configurations described below. A CFD analysis solves fundamental controlling equations and provides fluid velocity, species, combustion reactions, pressure, heat transfer and temperature values, etc. at every point in the solution domain.

FLUENT software from Fluent Inc. was used to perform the analysis.

(Fluent, Inc., USA, 10 Cavendish Court, Centerra Resource Park, Lebanon, N. H. , 03766-1442).

Example 1 [0085] In order to demonstrate the benefits of the present invention, the operation of a pre-mix burner employing a burner tip and flue gas recirculation system of the type described in U. S. Patent 5,092, 761 (as depicted in FIG. 5 of U. S. Patent 5,092, 761), was simulated to establish the baseline data using the FLUENT software package.

Example 2 [0086] In Example 2 the burner tip of the present invention is employed, with the same material balance maintained as in the existing burner. The temperature profile for the detailed material and energy balance calculated using the FLUENT computational fluid dynamics software showed a temperature profile that was, on average, lower than the profile exhibited by the configuration of Example 1. Experience has shown that this can be expected to reduce the NOx emissions of the burner.

Example 3 [0087] To further demonstrate the benefits of the present invention, a pre-mix burner, employing a burner tip in accordance with a preferred embodiment of the present invention was tested, wherein the fuel gas discharged from the burner tip during combustion from the peripherally arranged side ports was about 10 percent of the total fuel gas combusted.

The burner of this example also employing flue gas recirculation of the type described in U. S. Patent No. 5,092, 761 (as depicted in FIG. 5) and was operated at a firing rate of 6.3 kilojoules/hr (6 million BTU/hr), using a fuel gas comprised of 30% H2/70% natural gas, without steam injection.

[0088] A very stable flame was observed, with NOx emissions measured at 49 ppm.

Example 4 [0089] In this example, the pre-mix burner of Example 3 was used.

Once again, the burner employed flue gas recirculation of the type described in U. S. Patent No. 5,092, 761 and was operated at a firing rate of 6.3 kilojoules/hr (6 million BTU/hr), using a fuel gas comprised of 30% H2/70% natural gas, with steam injected at a rate of 60 Kg/hr (132 lb/hr).

[0090] A very stable flame was observed, with NOx emissions measured at 30 ppm.

Example 5 [0091] In this example, a pre-mix burner, employing a burner tip in accordance with another preferred embodiment of the present invention was tested, wherein the fuel gas discharged during combustion from the peripherally arranged side ports of the burner tip was about 5 percent of the total fuel gas combusted. The burner tested also employed flue gas recirculation of the type described in U. S. Patent No. 5,092, 761 (as depicted in FIG. 5) and was operated at a firing rate of 6.3 kilojoules/hr (6 million BTU/hr), using a fuel gas comprised of 30% H2/70% natural gas, without steam injection. A less stable flame than that of Example 3 was observed, with NOx emissions measured at 45 ppm, for an 8% reduction over the burner design tested in Example 3.

Example 6 [0092] In this example, the pre-mix burner of Example 5 was used.

Once again, the burner employed flue gas recirculation of the type described in U. S. Patent No. 5,092, 761 and was operated at a firing rate of 6.3 kilojoules/hr (6 million BTU/hr), using a fuel gas comprised of 30% H2/70% natural gas, with steam injected at a rate of 60 kg/hr (132 Ib./hr).

[0093] A less stable flame than that of Example 3 was observed, with NOx emissions measured at 28 ppm, for a 7% reduction over the burner design tested in Example 4.

[0094] It is to be understood that the burner tip and burner tip seal designs described herein also have utility in raw gas burners having a pre- mix burner configuration wherein flue gas alone is mixed with fuel at the entrance to the burner tube. In fact, it has been found that the pre-mix, staged-air burners of the type described in detail herein can be operated with the primary air damper doors closed with very satisfactory results.

[0095] In addition to the use of flue gas as a diluent, another technique to achieve lower flame temperature through dilution is through the use of steam injection. (See steam injection tube 15 of FIG. 2 and steam injection tube 184 of FIG. 15). Steam can be injected in the primary air or the secondary air chamber. Preferably, steam may be injected upstream of the venturi.

[0096] As may be appreciated by those skilled in the art, the present invention can be incorporated in new burners or can be retrofitted into existing burners.

[0097] Although illustrative embodiments have been shown and described, a wide range of modification change and substitution is contemplated in the foregoing disclosure and in some instances, some features of the embodiment may be employed without a corresponding use of other features. Accordingly, it is appropriate that the appended claims be construed broadly and in a manner consistent with the scope of the embodiments disclosed herein.