AU2009202864A9

AU2009202864A9 - Burner apparatus and methods

Info

Publication number: AU2009202864A9
Application number: AU2009202864A
Authority: AU
Inventors: Wesley R. Bussman
Original assignee: John Zink Co LLC
Current assignee: John Zink Co LLC
Priority date: 2008-07-25
Filing date: 2009-07-14
Publication date: 2012-07-05
Also published as: JP2010048544A; CN101634450A; EP2148138A3; EP2148137A3; EP2148138A2; MX2009007707A; TW201009261A; AU2009202864A1; AR072609A1; KR20100011921A; EP2148137A2; BRPI0902485A2; US20100021853A1

Abstract

A burner assembly for and method of combusting fuel gas in a furnace is provided. The burner assembly includes a burner tile having a burner throat disposed therethrough. Combustion air is conducted through the burner throat into a combustion zone in the furnace. A pilot assembly is used to generate a pilot flame within the burner throat. Fuel gas is injected into an ignition zone located outside the burner throat and ignited therein. The pilot flame generated in the burner throat can be used to ignite the fuel gas in the ignition zone. The ignited fuel gas is admixed with combustion air in the combustion zone. The burner assembly can be operated without admixing a significant amount of fuel gas with combustion air in the burner throat, which can help control the formation of undesirable nitrogen oxides (NOx). + 3/11 62,62a 144 80 118 118 80 62,62a 34b 18 22,74,78- 4a34 48 22,74,78 80 144 11181012114,118 1480 34 I1 \ 34a 22,74,78 ,'1.22,74,78

Description

AUSTRALIA Patents Act COMPLETE SPECIFICATION (ORIGINAL) Class Int. Class Application Number: Lodged: Complete Specification Lodged: Accepted: Published: Priority Related Art: Name of Applicant: John Zink Company, LLC Actual Inventor(s): Wesley R. Bussman Address for Service and Correspondence: PHILLIPS ORMONDE FITZPATRICK Patent and Trade Mark Attorneys 367 Collins Street Melbourne 3000 AUSTRALIA Invention Title: BURNER APPARATUS AND METHODS Our Ref: 857697 POF Code: 458443/481557 The following statement is a full description of this invention, including the best method of performing it known to applicant(s): -1- 2 BURNER APPARATUS AND METHODS This application claims priority from US Application No. 12/220,623 filed on 25 July 2008, the contents of which are to be taken as incorporated herein by this reference. BACKGROUND OF THE INVENTION [0001] Burner assemblies are used in many applications. For example, process burner assemblies are used in connection with industrial furnaces in petroleum refineries, chemical plants and similar facilities. The specific type and configuration of burner assemblies used will vary depending on the specific application, the type of furnace, the applicable emissions regulations and other factors known to those skilled in the art. [0002] A typical process burner includes a burner tile having a burner throat extending therethrough. The burner tile extends into the furnace. Combustion air is conducted through the burner throat to create a combustion zone in the furnace adjacent to the outlet of the burner throat. Fuel is injected into the burner throat, admixed with the combustion air and burned in the combustion zone. 100031 Many government authorities have adopted regulations relating to the amount of nitrogen oxides (commonly designated as "NOx" and primarily including NO and NO 2 ) and other potentially polluting compounds that can be emitted into the atmosphere from process furnaces and other combustion equipment. The United States, for example, has stringent regulations relating to nitrogen oxides emissions. These regulations have led to the development of burner apparatus and corresponding methods of operation that result in significantly lower nitrogen oxide emissions. [0004] In one approach, the fuel admixed with combustion air in the burner throat (commonly referred to as primary fuel) is burned in a first combustion zone. Additional fuel (often referred to as secondary or staged fuel) is burned in a second combustion zone. In such a burner assembly, the secondary or staged fuel becomes dilute with furnace flue gas thereby lowering the combustion temperature of the gases. The flue gas functions as a heat sink in that it absorbs heat from the flame. The flue gas can come from the furnace stack (external flue gas) or from the furnace itself (internal flue gas). Lowering the combustion temperature of the gases lowers the formation of nitrogen oxides in the produced flue gases. Secondarily, flue gas admixed with the combustion reactants reduces the species concentration of oxygen necessary for nitrogen oxide formation, thereby contributing to further nitrogen oxide reduction.

3 100051 It has been thought heretofore that it is necessary to admix primary fuel with combustion air in the throat of the burner, even in staged combustion burner assemblies. The primary fuel in the throat of the burner helps assure that the mixture of fuel and combustion air is ignited in the combustion zone and helps stabilize the burner. Unfortunately, in some applications, the admixture of primary fuel with combustion air in the throat of the burner can generate temperatures therein that are high enough to allow nitrogen oxides to form. Of secondary importance, the combustion air in the burner throat includes a substantially higher concentration of oxygen than the concentration of oxygen in flue gas. Combining a relatively high concentration of oxygen in the burner throat with higher temperatures caused by introducing primary fuel to the burner throat can cause a significant amount of nitrogen oxides to form. This diminishes the significance of the other steps taken to reduce the formation of nitrogen oxides. SUMMARY OF THE INVENTION 100061 The invention provides a burner assembly for a furnace. The invention also provides a method of using a burner assembly that includes a burner tile and a burner throat extending therethrough to combust fuel gas in a furnace space in order to generate heat. [00071 In a first aspect, the inventive burner assembly comprises a burner tile for association with the furnace, a burner pilot assembly and a fuel injection assembly. [0008] The burner tile of the first aspect of the burner assembly includes an exterior surface to be positioned within the furnace, and a burner throat disposed through the burner tile. The burner throat has an inlet and an outlet. The inlet of the burner throat is adapted to receive combustion air from outside the burner throat. The outlet of the burner throat is positioned adjacent to the exterior surface of the burner tile, and is positioned to introduce combustion air into a combustion zone located within the furnace and adjacent to the exterior surface of the burner tile. [00091 The burner pilot assembly of the first aspect of the burner assembly is for generating a pilot flame within the burner throat. The burner pilot assembly includes a pilot fuel tip and a pilot fuel riser. The pilot fuel riser has an inlet adapted to be fluidly connected to a source of fuel, and an outlet fluidly connected to the pilot fuel tip. The pilot fuel tip is disposed within the burner throat. [00101 The fuel injection assembly of the first aspect of the burner assembly is adapted to inject essentially all of the fuel needed for operation of the burner assembly into the furnace from one or more fuel tips located outside the burner throat. The fuel injection 4 assembly includes a main fuel tip and a main fuel riser for injecting main fuel into an ignition zone located within the furnace and adjacent to the exterior surface of the burner tile. The main fuel riser has an inlet adapted to be fluidly connected to a source of fuel, and an outlet fluidly connected to the fuel tip. The fuel tip is at least partially disposed within the furnace and positioned adjacent to the exterior surface of the burner tile. 100111 In a second aspect, the inventive burner assembly includes a burner tile for association with the furnace, an ignition passageway, a burner pilot assembly and a fuel injection assembly. [00121 The burner tile of the second aspect of the burner assembly includes an exterior surface to be positioned within the furnace and a burner throat disposed through the burner tile. The burner throat has an inlet and an outlet. The inlet of the burner throat is adapted to receive combustion air from outside the burner throat. The outlet of the burner throat is positioned adjacent to the exterior surface of the burner tile, and positioned to introduce combustion air into a combustion zone located within the furnace and adjacent to the exterior surface of the burner tile. 100131 The ignition passageway of the second aspect of the burner assembly extends through the burner tile between the burner throat and the exterior surface of the burner tile, and has an inlet and an outlet. The inlet of the ignition passageway is positioned adjacent to the burner throat, and the outlet of the ignition passageway is positioned adjacent to the exterior surface of the burner tile. [00141 The burner pilot assembly of the second aspect of the burner assembly is for generating a pilot flame within the burner throat. The burner pilot assembly includes a pilot fuel tip and a pilot fuel riser. The pilot fuel riser has an inlet adapted to be fluidly connected to a source of fuel, and an outlet fluidly connected to the pilot fuel tip. The pilot fuel tip is disposed within the burner throat. [00151 The fuel injection assembly of the second aspect of the burner assembly is adapted to inject fuel into the furnace from one or more fuel tips located outside of the burner throat. The fuel injection assembly includes a main fuel tip and a main fuel riser for injecting main fuel into an ignition zone located within the furnace and adjacent to the exterior surface of the burner tile. The main fuel riser has an inlet adapted to be fluidly connected to a source of fuel, and an outlet fluidly connected to the main fuel tip. The main fuel tip is at least partially disposed within the furnace and positioned adjacent to the exterior surface of the burner tile.

5 10016] The ignition passageway of the second aspect of the burner assembly receives at least a portion of the pilot flame generated by the burner pilot assembly, and conducts the flame, or portion thereof, to the ignition zone such that the flame or portion thereof can contact and ignite the main fuel injected by the main fuel tip into the ignition zone. 100171 In a first aspect, the inventive method is carried out without admixing a significant amount of fuel with combustion air in the burner throat. The method comprises the following steps: (a) conducting combustion air through the burner throat into a combustion zone located within the furnace, and adjacent to the exterior surface of the burner tile; (b) generating a pilot flame in the burner throat with pilot fuel provided by a burner pilot assembly; (c) injecting essentially all of the fuel needed for operation of the burner assembly into the furnace from one or more fuel tips located outside of the burner throat, the one or more fuel tips including a main fuel tip for injecting main fuel into an ignition zone located within the furnace, and adjacent to the exterior surface of the burner tile; (d) igniting main fuel in the ignition zone; and (e) admixing ignited main fuel with combustion air conducted through the burner throat in the combustion zone. 100181 In a second aspect, the inventive method comprises the following steps: (a) conducting combustion air through the burner throat into a combustion zone located within the furnace, and adjacent to the exterior surface of the burner tile; (b) generating a pilot flame in the burner throat with pilot fuel provided by a burner pilot assembly; (c) injecting fuel into the furnace from one or more fuel tips located outside of the burner throat, the one or more fuel tips including a main fuel tip for injecting main fuel into an ignition zone located within the furnace and adjacent to the exterior surface of the burner tile; (d) conducting at least a portion of the pilot flame from the burner throat to the ignition zone and using said pilot flame, or portion thereof, to ignite main fuel in the ignition zone; and 6 (e) admixing ignited main fuel with combustion air conducted through the burner throat into the combustion zone. BRIEF DESCRIPTION OF THE DRAWINGS [00191 FIG. 1 is a front perspective view of the inventive burner assembly. [0020] FIG. 2 is a section view of the inventive burner assembly taken along line 2-2 in FIG. 1. FIG. 2 also illustrates the flow of combustion air and the flame generated by the burner pilot assembly the inventive burner assembly. [00211 FIG. 3 is a front view of the inventive burner assembly and further illustrates the deflection of a flame across the exterior of the burner tile. [00221 FIG. 4 is an enlarged detail view of the burner tile exterior shown by FIG. 3. [00231 FIG. 5 is a partial top view of the inventive burner assembly. [00241 FIG. 6 is an enlarged front perspective view of a turning member and stabilizing member of the inventive burner assembly. [00251 FIG. 7 is a section view taken along line 7-7 in FIG. 6. [00261 FIG. 8 is a section view of an alternative configuration of the inventive burner assembly. [00271 FIG. 9 is a section view of another configuration of the inventive burner assembly. [00281 FIG. 10 is a section view of yet another configuration of the inventive burner assembly. [00291 FIG. 1 IA is a front view of the burner tile exterior and illustrates an alternative embodiment of the inventive burner assembly. [00301 FIG. 1 B is a partial top view of the embodiment shown by FIG. 1 A. [00311 FIG. 1 C is a section view taken along line 1 C-I IC of FIG. 1 IA. [00321 FIG. 12A is a front view of the burner tile exterior and illustrates another alternative embodiment of the inventive burner assembly. [0033] FIG. 12B is a partial top view of the embodiment of the inventive burner assembly shown by FIG. 12A. [00341 FIG. 12C is a section view taken along line I IC-I IC of FIG. 12A. [00351 FIG. 13A is a front view of the burner tile exterior and illustrates yet another alternative embodiment of the inventive burner assembly. [00361 FIG. 13B is partial top view of the embodiment of the inventive burner assembly shown by FIG. 13A.

7 100371 FIG. 13C is a section view taken along line IIC- I1C of FIG. 13A. DETAILED DESCRIPTION 100381 Referring to the drawings, the inventive burner assembly is illustrated and generally designated by the numeral 10. As shown by the drawings and understood by those skilled in the art, the burner assembly 10 and components thereof are designed to be associated with a furnace 12 (the overall furnace is not shown) and can be used to generate heat in a petroleum refinery, chemical plant or other applications. The burner assembly 10 is attached to a wall 14 of the furnace 12 (for example, a side wall, bottom wall (or floor) or top wall (or ceiling)) and extends into a furnace space 16 of the furnace. The burner assembly 10 can also freely stand in the furnace 12, for example on the floor of the furnace. The furnace wall 14 includes an internal layer of insulating material 14(a) attached thereto. 100391 The burner assembly 10 shown by FIGS. I and 2 is attached to and horizontally associated with a side wall 14 of a furnace and fired upwardly (up-fired) with respect thereto. As discussed further below, the burner assembly 10 can be configured and associated with the furnace 12 in other ways as well. The burner assembly 10 discharges a mixture of fuel gas and air into furnace space 16 where the mixture is burned in the presence of flue gas while producing a relatively low content of nitrogen oxides (NOx) and carbon products. Typically, multiple burner assemblies 10 are installed in a single furnace 12. [00401 The burner assembly 10 comprises a burner tile 18 for association with the furnace 12, a burner pilot assembly 20 and a fuel injection assembly 22. As understood by those skilled in the art, the burner assembly 10 can be a natural draft burner (i.e., the air required for combustion is naturally drafted into burner tile 18), a forced draft burner (for example, a blower is used to blow the combustion air into burner tile 18), a balanced draft burner (for example, blowers are used to blow air both in and out of the burner to achieve an appropriate balance of combustion air) or variations thereof. 100411 The burner tile 18 includes a base 24, and an exterior surface 26 to be positioned within the furnace 12 (to extend within the furnace space 16). The exterior surface 26 includes a top section 28, a bottom section 30, and a sidewall section 32 connecting the top section to the bottom section. The base 24 of the burner tile 18 is attached to the furnace wall 14. The bottom section 30 is slightly tapered from the base 24 to the sidewall section 32. The sidewall section 32 includes a front face 34 and side faces 36. The front face 34 includes a lower front face 34(a) and a sloped front face 34(b). The sloped front face 34(b) 8 tapers inwardly from the lower front face 34(a) to the top section 28 of the exterior surface 26 of the burner tile 18. 10042] As illustrated in the drawings, the burner assembly 10 is a natural draft burner (i.e., the air required for combustion is naturally drafted into burner tile 18). A plenum 38 is attached to the back of the furnace wall 14 and to the base 24 of the burner tile 18 to provide combustion air (illustrated in the drawings by arrows 40) from outside the furnace 12 to the burner assembly 10. The plenum 38 includes an air inlet 42. A damper assembly 44 is attached to the air inlet 42 for regulating the amount of air that is introduced into the plenum 38 and burner assembly 10. An air opening 46 extends through the furnace wall 14 to allow air to be conducted from the plenum 38 to the burner tile 18. 100431 A burner throat 48 is disposed through the burner tile 18. The burner throat 48 includes a throat wall 50 that defines and surrounds burner throat. The burner throat 48 has an inlet 52 and an outlet 54. The inlet 52 is adapted to receive combustion air (designated by arrows 40) from outside of the burner throat 48 (specifically, the plenum 38). The inlet 52 of the burner throat 48 is aligned over the air opening 46 extending through the furnace wall 14, thereby providing fluid communication between the burner throat 48 and the plenum 38. The outlet 54 of the burner throat 48 is positioned adjacent to the exterior surface 26 of the burner tile, and is positioned to introduce combustion air (designated by the arrows 40) into a combustion zone 58 located within the furnace 12 and adjacent to the exterior surface of the burner tile 18. Combustion air is discharged into the combustion zone 58 in the furnace 12 through the outlet 54 of the burner throat 48. 100441 The wall 50 of the burner throat 48 extends inwardly adjacent to the outlet 54 of the burner throat 48 to form a throat ledge 60. The throat ledge 60 functions to stabilize the flame. 100451 The burner pilot assembly 20 is utilized to generate a pilot flame 62 within the burner throat 48. The burner pilot assembly 20 includes a pilot fuel riser 64 and a pilot fuel tip 66. The pilot fuel riser 64 has an inlet 68 adapted to be connected to a source of fuel 70, and an outlet 72 fluidly connected to the pilot fuel tip 66. The pilot riser extends through the air opening 46 in the furnace wall 14 into the burner throat 48. The pilot tip 66 is disposed within the burner throat 48. Preferably, the burner pilot assembly 20 pre-mixes the fuel with oxygen in the burner pilot assembly prior to generating the flame 62. This can be accomplished, for example, by using a mixer jet at the inlet of the pilot riser. The motive force of the fuel in the mixer jet draws in and admixes air (including oxygen) with the fuel.

9 [0046] The fuel injection assembly 22 is preferably adapted to inject essentially all of the fuel needed for operation of the burner assembly 10 into furnace 12 from one or more fuel tips 74 located outside of the burner throat. As used herein and in the appended claims, "essentially all" of the fuel needed for operation of the burner assembly 10 means all of the fuel needed to operate the burner except for fuel used in operating the burner pilot assembly 20. The fuel injection assembly 22 includes main fuel risers 76 and main fuel tips 78 for injecting main fuel into ignition zones 80 located within the furnace 12 and adjacent to the exterior surface 26 of the burner tile 18. The main fuel risers 76 have inlets 82 adapted to be fluidly connected to a source of fuel 84, and outlets 86 fluidly connected to the main fuel tips 78. Preferably, the portions of the main fuel risers 76 that would otherwise extend into the furnace 14 are disposed through the burner tile 18. The main fuel tips 78 are at least partially disposed within the furnace 12 and positioned adjacent to the lower front face 34(a)of the front face 34 of the sidewall section 32 of the burner tile 18. The main fuel tips 78 are positioned to inject main fuel along the front face 34 into the ignition zones 80. The ignition zones 80 are positioned adjacent to the sloped front face 34(b) of the front face 34. A plurality of main fuel risers 76 and main fuel tips 78 and a plurality of ignition zones 80 can be used. FIGS. I and 3-5 all depict two main fuel risers 76 and two corresponding main fuel tips 78, each injecting main fuel toward a separate ignition zone 80. [00471 The fuel injection assembly 22 also includes a supplemental fuel injection assembly 90. The supplemental fuel injection assembly 90 is positioned to inject supplemental fuel into the combustion zone 58. The supplemental fuel injection assembly 90 includes supplemental fuel risers 92 and supplemental fuel tips 94. The supplemental fuel risers 92 have inlets 98 that are adapted to be fluidly connected to a source of fuel 100, and outlets 102 that are fluidly connected to the supplemental fuel tips 94. The supplemental fuel risers 92 are partially disposed through the burner tile 18 and extend into troughs 104 that are disposed in the burner tile 18. Each trough 104 includes a trough wall 106 and a trough outlet 108. The supplemental fuel risers 92 extend through the walls 106 of the troughs 104. The supplemental fuel tips 94 are positioned within the troughs 104 and positioned to inject supplemental fuel into the combustion zone 58 through the outlets 108 of the troughs. A plurality of supplemental fuel risers 92, supplemental fuel tips 94 and corresponding troughs 104 can be utilized. As depicted, the fuel injection assembly 22 includes two supplemental fuel risers 92, two supplemental fuel tips 94 and two corresponding troughs 104.

10 100481 The burner assembly 10 further comprises ignition passageways 114 for receiving at least a portion of the flame 62 generated by the burner pilot assembly 20. The ignition passageways 114 conduct the flame 62 or portion thereof to the ignition zones 80 whereby the flame 62 or portion thereof can ignite main fuel injected by the main fuel tips 78 into the ignition zones. The ignition passageways 114 extend through the burner tile 18 between the burner throat 48 and the exterior surface 26 of the burner tile 18, specifically the sloped front face 34(b) of the front face 34 of the sidewall section 32 of the exterior surface 26 of the burner tile 18. The ignition passageways 114 include inlets 116 positioned adjacent to the burner throat 48, and outlets 118 positioned adjacent to the sloped front face 34(b). 100491 As illustrated, each ignition passageway 114 receives a portion 62(a) of the flame 62 and conducts the flame portion 62(a) to an ignition zone 80. The flame portions 62(a) contact and ignite main fuel injected by the main fuel tips 78 into the ignition zones 80. A plurality of ignition passageways 114 may be used. As illustrated, the burner assembly includes two ignition passageways 114. [00501 The burner assembly 10 further comprises flame diverters 124 for causing at least a portion of the flame 62 generated by the burner pilot assembly 20 to be diverted into the ignition passageways 114. As illustrated, the flame diverters 124 are adapted to cause a portion of the flame 62 generated by the burner pilot assembly 20, flame portion 62(a), to be diverted into the ignition passageways 114, and a portion of the flame 62 generated by said burner pilot assembly, flame portion 62(b), to be conducted through the outlet 54 of the burner throat 48 into the combustion zone 58. The relative amounts of the flame 62 forming the flame portions 62(a) and 62(b) can be adjusted as necessary. For example, the amount of the flame 62 diverted into flame portions 62(a) needs to be sufficient to allow the flame portions 62(a) to reach the ignition zones 80 and ignite main gas therein. [00511 In the embodiment of the burner assembly 10 shown by FIGS. 1-7, the flame diverters 124 are impingement blocks 126 that are attached to the wall 50 of the burner throat 48 adjacent to the ignition passageway inlets 116. The impingement blocks 126 split the flame 62 into flame portions 62(a) and 62(b). They can also be configured to divert the entire pilot flame 62 into the ignition passageways 114. [0052] As best shown by FIGS. 4-7, the flame portions 62(a) that are conducted through the ignition passageways 114 are also manipulated on the outside of the burner tile. In this respect, the burner assembly 10 includes turning members 140, the turning members 140 II being located adjacent to the exterior surface 26 of the burner tile 18 and positioned to redirect the flame portions 62(a) from the outlets 118 of the ignition passageways across the exterior surface of the burner tile. In one embodiment, the turning members 140 are turning blocks 142 that are positioned on the sloped front face 34(b) of the front face 34 of the sidewall section 32 of the exterior surface 26 over the ignition passageway outlets 118. The flame portions 62(a) conducted through the ignition passageway outlets 118 impinge on the turning blocks 142 and are redirected through channels 144 that are disposed in the front sloped front face 34(b) across the sloped front face 34(b). [00531 Stabilizing members 150 are positioned on the exterior surface 26 of the burner tile 18 to receive the flame portions 62(a) (or a portion thereof) and facilitate contact of the received flame with main fuel injected by the main fuel tips 78. Specifically, each stabilizing member 150 is attached to a corresponding turning block 142 and extends substantially perpendicularly therefrom below the corresponding channel 144 and along the sloped front face 34(b). The stabilizing members 150 act as bluff bodies in that they receive both the flames (or a portion thereof) from the turning blocks 142 and main fuel that is discharged from the main fuel tips 78. Main fuel discharged from the main fuel tips 78 is caused to slow down or impinge on the stabilizing members 150 where it is ignited by the flames. [00541 A plurality of turning blocks 142, channels 144 and stabilizing members 150 can be utilized. As illustrated, a turning block 142, channel 144 and stabilizing member 150 are used in association with each of the two ignition passageways 114. [00551 Referring now to FIGS. 8-10, additional configurations of the burner assembly 10 are illustrated. As mentioned above, the burner assembly 10 can be configured and associated with the furnace 12 in various ways. For example, the burner assembly 10 can be associated with the furnace 12 horizontally or vertically and can be fired upwardly (up fired) or fired downwardly (down-fired). The burner assembly 10 can be associated with the furnace 12 at any orientation. [00561 As shown by FIGS. I and 2, the burner assembly 10 is designed and configured to be horizontally mounted on a wall 14 of the furnace 12 and vertically fired adjacent to a side wall of the furnace. FIG. 8 illustrates a design and configuration of the burner assembly 10 that is adapted to be vertically mounted on a wall 14 of the furnace 12 and vertically fired adjacent to a side wall of the furnace. The inventive burner assembly shown by FIG. 8 is fired along the side wall of the furnace. For example, unlike the burner throat 12 48 illustrated by FIGS. I and 2, the burner throat 48 in the configuration shown by FIG. 8 is not "L" shaped but is straight. 100571 FIG. 9 illustrates a design and configuration of the burner assembly 10 that is adapted to be vertically mounted on the floor 14 of the furnace and vertically fired into the interior 160 of the furnace. The inventive burner assembly shown by FIG. 9 can be attached or free standing in a middle area 162 of the interior 160 of the furnace. This configuration includes multiple main fuel tips and risers, ignition passageways and corresponding components. It does not include the troughs 104 and corresponding components for supplemental fuel injection. 100581 FIG. 10 illustrates a design and configuration of the burner assembly 10 that is similar to the inventive burner assembly shown by FIG. 9, except in this configuration the inventive burner assembly is adapted to be vertically mounted from the ceiling 14 of the furnace 12 and vertically down fired into a middle area 162 of the interior 160 of the furnace. [00591 Referring now to FIGS. I 1A-I IC, an alternative embodiment of the inventive burner assembly 10 is illustrated. In this embodiment, the ignition passageways 114 include Coanda surfaces 170 adjacent to the inlets 116 for causing at least a portion of the flame 62 generated by the burner pilot assembly 20 to be diverted into the ignition passageways 114. As a result, the flame diverters 124 are not necessarily needed. The flame 62 emitted from the pilot tip 66 or a portion thereof (depending on the velocity of the flame, the curvature of the Coanda surfaces and other factors known to those skilled in the art) adheres to and follows the path of the Coanda surfaces 170 into the ignition passageways 114. The Coanda surfaces 170 can be utilized in association with flame diverters 124 if desired. [00601 As illustrated by FIGS. I IA-I IC, the ignition passageways 114 can also include Coanda surfaces 174 adjacent to the outlets 118 of the ignition passageways 114 for causing at least a portion of the flame portions 62(a) conducted through the outlets 118 to be redirected across the sloped front face 34(b) of the front face 34 of the sidewall section 32 of the exterior surface 26 of the burner tile 18. As a result, the turning members 140 are not necessarily needed. The flame portions 62(a) conducted through the outlets 118 of the ignition passageways 114 adhere to and follow the paths of the Coanda surfaces 174 such that they are received by the stabilizing member 150. In this embodiment, the stabilizing member 150 is a ledge 178 positioned below the outlets 118. Turning members 140 can still be utilized if desired.

13 [00611 Referring now to FIGS. 12A-12C, another alternative embodiment of the inventive burner assembly 10 is illustrated. In this embodiment, the flame diverters 124 are fluid injection assemblies 180 associated with the ignition passageways 114 for injecting fluid into the ignition passageways toward the ignition zones 80 to create pressures in the injection passageways 114 that are lower than the pressure in the burner throat 48. The relatively low pressures in the injection passageways draw the pilot flame 62 or a portion thereof (flame portions 62a) into the injection passageways 114. The fluid injection assemblies 180 are adapted to be fluidly connected to a source of fuel 182 whereby the fluid injection assemblies can inject fuel into the ignition passageways 114. As best shown by FIG. 12C, fuel eductor passageways 190 are formed in the burner tile 18. Each fluid eductor passageways 190 extends from a main fuel riser 76 to the corresponding ignition passageway 114. An inlet 192 of each fuel eductor passageway 190 is fluidly connected to and receives main fuel from the corresponding main fuel riser 76. An outlet 194 of each fuel eductor passageway 190 is fluidly connected to the corresponding ignition passageway 114. In this way, fuel can be directly injected from the main fuel risers 76 into the ignition passageways 114 to educt the pilot flame 62 or a portion thereof into the ignition passageways. The main fuel in the fuel eductor passageways 190 is either ignited by the flame 62 and burned in the passageways or ignited and burned in the ignition zones. 10062] Referring now to FIGS. 13A-13C, another alternative embodiment of the inventive burner assembly 10 is illustrated. In this embodiment, the ignition passageways 114 are disposed through the burner tile 18 at angles diverging radially outward from the burner throat 48. In this embodiment, the passageways 114 diverge radially outwardly at much greater angles from the burner throat 48 (as compared to the angles at which the passageways 114 diverge radially outwardly from the burner throat 48 as shown in FIG. 5). This places the flames emitted from the passageways 114 in closer proximity to the main fuel tips 78 and helps direct the flames across the sloped front face 34(b). Due to the location of the outlets 118 and the angle of injection of the flame therefrom, the turning members 140 are not necessarily needed. The flame portions 62(a) conducted through the outlets 118 of the ignition passageways 114 are received by stabilizing members 196. The stabilizing members 196 are ledges 198 positioned below the outlets 118. Turning members 140 can still be utilized if desired.

14 100631 The sloped front face 34(b) can be steeply sloped or gently sloped. One determining factor includes the pressure used to inject main fuel from main fuel tips 78 onto the sloped front face 34(b). Operation of the Inventive Burner Assembly [00641 A variety of different types of fuels can be burned by the inventive burner assembly 10, including natural gas, methane, hydrogen, propane, propylene, ethane, ethylene, butane, butane, butylene, other typical refinery-type fuels and mixtures thereof. Preferably the fuel is in gaseous form, although with a fuel atomizer and other equipment as known in the art liquid fuel can be used. 100651 The inventive burner assembly 10 can be used to combust fuel in the furnace space 16 in order to generate heat without admixing a significant amount of fuel with combustion air in the burner throat 48. As used herein and in the appended claims, "without admixing a significant amount of fuel with combustion air in the burner throat 48" means without adding fuel (e.g., primary fuel) to the burner throat except for fuel added to the burner throat in connection with generating the pilot flame 62 therein. 100661 The inventive burner assembly 10 is attached to the furnace wall 14 such that the exterior surface of the burner tile 18 extends into the furnace space 16. The burner assembly 10 can also freely stand in the interior of the furnace 12. As explained above, combustion air (illustrated in the drawings by arrows 40) is provided to the burner throat inlet 52 from plenum 38 through the air opening 46. [00671 Combustion air is conducted from the plenum 38 into the burner throat 48 and through the outlet 54 of the burner throat into the combustion zone 58. The combustion zone 58 is located within the furnace 12 and adjacent to exterior surface 26 of burner tile 18. A pilot flame 62 is generated within burner throat 48 with pilot fuel provided by the burner pilot assembly 20. Prior to generating the pilot flame, oxygen is pre-mixed with the pilot fuel in the burner pilot assembly 20. 100681 Essentially all of the fuel needed for operation of burner assembly 10 is injected into the furnace 12 from fuel tips 74 located outside of burner throat 48. As stated above, as used herein and in the appended claims, "essentially all" of the fuel needed for operation of the burner assembly 10 means all of the fuel needed to operate the burner except for fuel used in operating the burner pilot assembly 20. The fuel tips 74 include main fuel tips 78. Main fuel tips 78 inject main fuel into the ignition zones 80 located within the furnace 12 and adjacent to the exterior surface 26 of burner tile 18. Main fuel is ignited in ignition 15 zones 80. The ignited main fuel is then admixed with combustion air in the combustion zone 58. The primary combustion of the fuel for generating heat in the furnace occurs in the combustion zone 58. [00691 In one embodiment, at least a portion of the pilot flame 62 generated in the burner throat 48 is used to ignite main fuel in the ignition zones 80. The pilot flame 62 or portion thereof is conducted into the ignition zones 80 through ignition passageways 114 extending through the burner tile 18 between the burner throat 48 and the exterior surface 26 of the burner tile whereby the pilot flame or portion thereof can contact and ignite fuel in the ignition zones 80. 100701 The pilot flame 62 or portion thereof is diverted into the ignition passageways 114. Preferably, first portions 62(a) of the pilot flame are diverted into the ignition passageways 114 and a second portion 62(b) of the pilot flame is allowed to be conducted through the burner throat 48 into the combustion zone 58. In one embodiment, the pilot flame or portions thereof are diverted into the ignition passageways by impinging the pilot flame or portions thereof on the flame diverters 124 located in the burner throat. In another embodiment, the ignition passageways 114 include Coanda surfaces, and the pilot flame 62or portions thereof are diverted into the ignition passageways by directing the pilot flame or portions thereof on the Coanda surfaces. In yet another embodiment, the pilot flame 62 or portions thereof are diverted into the ignition passageways 114 by causing the pressures in the ignition passageways to be lower than the pressure in the burner throat 48. The pressures in the ignition passageways 114 are preferably caused to be lower than the pressure in the burner throat 48 by injecting an eductor fluid into the ignition passageways toward the ignition zones 80. Preferably, the eductor fluid is fuel. [00711 The fuel tips 74 also include supplemental fuel tips 94 for injecting supplemental fuel into the combustion zone 58. Supplemental fuel is injected from the supplemental fuel tips 94 into the troughs 104 and into the combustion zone 58. As the supplemental fuel burns, it controls the flame in the combustion zone 58 by drawing the flame closer to the side wall 14 of the furnace 12. Use of the term "supplemental" herein should not be construed to mean that less fuel is conducted through the supplemental fuel tips 94 than through the main fuel tips 78. The volume of supplemental fuel discharged into the combustion zone 58 by the supplemental fuel tips 94 may exceed the volume of the main fuel discharged by the main fuel tips 78 in some applications.

16 [00721 In order to further illustrate the invention, the following example and test data are provided. [0073] The inventive burner assembly 10 was tested for performance. The burner assembly 10 that was tested was generally configured like the burner assembly 10 shown in FIGS. 1-7. [00741 The furnace 12 was cold when each test was started. The test data shown below was derived following a light-off procedure. The light-off procedure included the steps of opening the furnace damper, warming up the furnace with a heat release of about 0.75 MMBtu/hr for about 10 minutes at 12% 02, and then increasing the heat release to about 1.25 MMBtu/hr for about 30 minutes at 9% 02. [00751 During startup, main fuel was injected onto the sloped front face 34(b) and impinged on flame stabilizing members 150. A portion of the pilot flame 62 (pre-mixed with oxygen) was diverted through ignition passageways 114 by flame diverter 124. The diverted flame was discharged from the ignition passageway 114 and was redirected onto the flame stabilizing members 150 by turning blocks 142. The diverted flame and main fuel injected from the main fuel tips 78 made contact in the ignition zones 80, and main fuel was ignited therein. The ignited main fuel continued to flow upwardly over the sloped front face 34(b) into the combustion zone 58. A portion of the flame 62 exited the outlet 54 of the burner throat 48 thereby providing an additional source of ignition and stabilizing the burner. In the combustion zone 58, supplemental fuel, combustion air from the burner throat 48 and the ignited main fuel further combusted in a manner in which a relatively low level of nitrogen oxides were produced. [0076] The following test data was generated. Test Data Data Set 1 (light off): Fuel 100% TNG* Fuel Flow Rate 793.0 scfh Fuel Temperature 94 0 F Combustion Air Temperature 76 0 F Stack Temperature 648OF Furnace Temperature 799 0 F Lower Furnace Temperature 278OF Furnace Draft 0.24 in. H 2 0 dP Burner 0.21 in. H 2 0 Fuel Pressure 2.6 psig 17 Pre-Mixed Gas For Pilot Burner Heat Release 0.72 MMBtu/hr Bumer Flow Rate 793 scfh Burner Lower Heating Value 913.00 Btu/scf NOx Emissions 9.72 ppmvd CO Emissions 307.94 ppmvd 02 (Dry) 14.34%vd * Tulsa Natural Gas Data Set 2 (rapid warm up): Fuel 100% TNG* Fuel Flow Rate 1102.0 scfh Fuel Temperature 94 0 F Combustion Air Temperature 77 0 F Stack Temperature 796 0 F Furnace Temperature 960*F Lower Furnace Temperature 394 0 F Furnace Draft 0.25 in. H 2 0 dP Burner 0.23 in. H 2 0 Fuel Pressure 4.8 psig Pre-Mixed Gas For Pilot Burner Heat Release 1.01 MMBtu/hr Burner Flow Rate 1102 scfh Burner Lower Heating Value 913.00 Btu/scf NOx Emissions 9.99 ppmvd CO Emissions 653.77 ppmvd** 02 (Dry) 12.23%vd * Tulsa Natural Gas **this value can be substantially decreased with a slower warm- up rate Data Set 3 (normal operation, TNG*): Fuel 100% TNG* Fuel Flow Rate 1806.0 scfh Fuel Temperature 99 0 F Combustion Air Temperature 83 0 F Stack Temperature 1417*F Furnace Temperature 1573 0 F Lower Furnace Temperature 1249 0 F Furnace Draft 0.22 in. H 2 0 dP Burner 0.15 in. H 2 0 Fuel Pressure 12.1 psig 18 Pre-Mixed Gas For Pilot Burner Heat Release 1.65 MMBtu/hr Burner Flow Rate 1806 scfh Burner Lower Heating Value 913.00 Btu/scf NO, Emissions 10.92 ppmvd CO Emissions 0.0 ppmvd 02 (Dry) 4.01 %vd * Tulsa Natural Gas Data Set 4 (normal operation, high hydrogen fuel): Fuel 47.70% TNG* 20.79% Propane 31.51% H 2 Fuel Flow Rate 811.0 scfh TNG 353 scfh Propane 536 seth H 2 Fuel Temperature 5 06 0 F Combustion Air Temperature 82 0 F Stack Temperature 1448*F Furnace Temperature 1591 *F Lower Furnace Temperature 1283 0 F Furnace Draft 0.24 in. H 2 0 dP Burner 0.17 in. H 2 0 Fuel Pressure 12.1 psig Pre-Mixed Gas For Pilot Burner Heat Release 1.71 MMBtu/hr Burner Flow Rate 1701 scfh Burner Lower Heating Value 1003.00 Btu/scf NO, Emissions 20.27 ppmvd CO Emissions 0.0 ppmvd 02 (Dry) 3.88%vd * Tulsa Natural Gas Data Set 5 (normal operation, high hydrogen fuel with air pre-heat): Fuel 48.01% TNG* 20.47% Propane 31.53%

H

2 Fuel Flow Rate 818.0 scfh TNG 350 scfh Propane 537 scfh H 2 Fuel Temperature 120*F Combustion Air Temperature 554 0 F Stack Temperature 1525 0

F

19 Furnace Temperature 1674 0 F Lower Furnace Temperature 1361*F Furnace Draft 0.28 in. H 2 0 dP Burner 0.24 in. H 2 0 Fuel Pressure 14.0 psig Pre-Mixed Gas For Pilot Burner Heat Release 1.70 MMBtu/hr Burner Flow Rate 1704 scfh Burner Lower Heating Value 998.39.00 Btu/scf NO, Emissions 26.06 ppmvd CO Emissions 0.0 ppmvd 02 (Dry) 2.97%vd * Tulsa Natural Gas 10077] Thus, the inventive burner assembly 10 performed very well. Essentially no carbon monoxide emissions were observed during normal operation of the burner assembly. Nitrogen oxide emissions were very low. 100781 Other embodiments of the current invention will be apparent to those skilled in the art from a consideration of this specification or practice of the invention disclosed herein. Thus, the foregoing specification is considered merely exemplary of the current invention with the true scope thereof being defined by the following claims. 100791 Thus, the present invention is well adapted to carry out the objects and attain the ends and advantages mentioned and alluded to as well as those which are inherent therein. What is claimed is:

Claims

1. A burner assembly for a furnace comprising: a burner tile for association with the furnace, said burner tile including: an exterior surface to be positioned within the furnace; and a burner throat disposed through said burner tile, said burner throat having an inlet and an outlet, said inlet of said burner throat adapted to receive combustion air from outside said burner throat, said outlet of said burner throat being positioned adjacent to said exterior surface of said burner tile and positioned to introduce combustion air into a combustion zone located within said furnace and adjacent to said exterior surface of said burner tile; a burner pilot assembly for generating a pilot flame within said burner throat, said burner pilot assembly including a pilot fuel tip and a pilot fuel riser, said pilot fuel riser having an inlet adapted to be fluidly connected to a source of fuel and an outlet fluidly connected to said pilot fuel tip, said pilot fuel tip being disposed within said burner throat; and a fuel injection assembly adapted to inject essentially all of the fuel needed for operation of said burner assembly into said furnace from one or more fuel tips located outside of said burner throat, said fuel injection assembly including a main fuel tip and a main fuel riser for injecting main fuel into an ignition zone located within said furnace and adjacent to said exterior surface of said burner tile, said main fuel riser having an inlet adapted to be fluidly connected to a source of fuel and an outlet fluidly connected to said fuel tip, said fuel tip being at least partially disposed within said furnace and positioned adjacent to said exterior surface of said burner tile.

2. The burner assembly of claim 1, wherein said burner tile further includes an ignition passageway for receiving at least a portion of the flame generated by said burner pilot and conducting said flame or portion thereof to said ignition zone whereby said flame or portion thereof can contact and ignite main fuel injected by said main fuel tip into said injection zone, said injection passageway extending through said burner tile between said burner throat and said exterior surface of said burner tile and having an inlet and an outlet, said inlet of said ignition passageway being positioned adjacent to said burner throat and said outlet of said ignition passageway being positioned adjacent to said exterior surface of said burner tile. 21

3. The burner assembly of claim 2, wherein said burner pilot assembly is adapted to pre-mix oxygen with fuel in said burner pilot assembly prior to generating said flame.

4. The burner assembly of claim 2, wherein said ignition passageway includes a Coanda surface for causing at least a portion of the flame generated by said burner pilot assembly to be diverted into said ignition passageway.

5. The burner assembly of claim 2, further comprising a flame diverter for causing at least a portion of the flame generated by said burner pilot assembly to be diverted into said ignition passageway.

6. The burner assembly of claim 5, wherein said flame diverter is adapted to cause a portion of the flame generated by said burner pilot assembly to be diverted into said ignition passageway and a portion of the flame generated by said burner pilot assembly to be conducted through said outlet of said burner throat into said combustion zone.

7. The burner assembly of claim 5, wherein said flame diverter is an impingement member located in said burner throat.

8. The burner assembly of claim 7, wherein said flame diverter is a fluid injection assembly associated with said ignition passageway for injecting fluid into said ignition passageway toward said ignition zone.

9. The burner assembly of claim 8, wherein said fluid injection assembly is adapted to be fluidly connected to a source of fuel whereby said fluid injection assembly can inject fuel into said ignition passageway.

10. The burner assembly of claim 1, wherein said exterior surface of said burner tile includes a top section, a bottom section and a sidewall section connecting said top section to said bottom section.

11. The burner assembly of claim 10, wherein said main fuel combustion tip and said ignition zone are located adjacent to said sidewall section of said exterior surface of said burner tile.

12. The burner assembly of claim 11, wherein said fuel injection assembly further includes a supplemental fuel tip and supplemental fuel riser for injecting supplemental fuel into said combustion zone, said supplemental fuel riser having an inlet adapted to be fluidly connected to a source of fuel and an outlet connected to said supplemental fuel tip. 22

13. The burner assembly of claim 12, wherein said supplemental fuel riser is partially disposed through the burner tile and extends into a trough disposed in the burner tile that includes an outlet positioned adjacent to said combustion zone, and said supplemental fuel tip is disposed in said trough.

14. The burner assembly of claim 2, further comprising a turning member, said turning member located adjacent to said exterior surface of said burner tile and positioned to redirect said flame or a portion thereof from said outlet of said ignition passageway across said exterior surface of said burner tile.

15. The burner assembly of claim 14, further comprising a stabilizing member, said stabilizing member positioned on said exterior surface of said burner tile to receive said flame or a portion thereof and facilitate contact of said flame or a portion thereof with fuel injected by said main fuel tip.

16. The burner assembly of claim 15, wherein said stabilizing member is attached to said turning member and extends substantially perpendicularly therefrom along said exterior surface of said burner tile, and said stabilizing member receives said flame or a portion thereof from said turning block.

17. The burner assembly of claim 1, wherein said fuel injection assembly further includes a supplemental fuel tip and supplemental fuel riser, said supplemental fuel riser having an inlet adapted to be fluidly connected to a source of fuel and an outlet connected to said supplemental fuel tip, said supplemental fuel tip being at least partially disposed within said furnace and positioned to discharge said supplemental fuel into said combustion zone.

18. A burner assembly for a furnace comprising: a burner tile for association with the furnace, said burner tile including: an exterior surface to be positioned within the furnace; and a burner throat disposed through said burner tile, said burner throat having an inlet and an outlet, said inlet of said burner throat adapted to receive combustion air from outside said burner throat, said outlet of said burner throat being positioned adjacent to said exterior surface of said burner tile and positioned to introduce combustion air into a combustion zone located within said furnace and adjacent to said exterior surface of said burner tile; an ignition passageway extending through said burner tile between said burner throat and said exterior surface of said burner tile and having an inlet and an outlet, said inlet of said ignition passageway being positioned adjacent to said burner throat and 23 said outlet of said ignition passageway being positioned adjacent to said exterior surface of said burner tile; a burner pilot assembly for generating a pilot flame within said burner throat, said burner pilot assembly including a pilot fuel tip and a pilot fuel riser, said pilot fuel riser having an inlet adapted to be fluidly connected to a source of fuel and an outlet fluidly connected to said pilot fuel tip, said pilot fuel tip being disposed within said burner throat; and a fuel injection assembly adapted to inject fuel into said furnace from one or more fuel tips located outside of said burner throat, said fuel injection assembly including a main fuel tip and a main fuel riser for injecting main fuel into an ignition zone located within said furnace and adjacent to said exterior surface of said burner tile, said main fuel riser having an inlet adapted to be fluidly connected to a source of fuel gas and an outlet fluidly connected to said main fuel tip, said main fuel tip being at least partially disposed within said furnace and positioned adjacent to said exterior surface of said burner tile, whereby said ignition passageway receives at least a portion of said pilot flame generated by said burner pilot assembly and conducts said flame or portion thereof to said ignition zone such that said flame or portion thereof can contact and ignite main fuel injected by said main fuel tip into said ignition zone.

19. The burner assembly of claim 18, wherein said fuel injection assembly is adapted to inject essentially all of the fuel needed for operation of said burner assembly into said furnace from one or more fuel tips located outside of said burner throat.

20. The burner assembly of claim 18, wherein said burner pilot assembly is adapted to pre-mix oxygen with pilot fuel in said burner pilot assembly prior to generating said flame.

21. The burner assembly of claim 18, wherein said ignition passageway includes a Coanda surface for causing at least a portion of the flame generated by said burner pilot assembly to be diverted into said ignition passageway.

22. The burner assembly of claim 18, further comprising a flame diverter for causing at least a portion of the flame generated by said burner pilot assembly to be diverted into said ignition passageway.

23. The burner assembly of claim 22, wherein said flame diverter is adapted to cause a portion of the flame generated by said burner pilot assembly to be diverted into said 24 ignition passageway and a portion of the flame generated by said burner pilot assembly to be conducted through said outlet of said burner throat into said combustion zone.

24. The burner assembly of claim 22, wherein said flame diverter is an impingement member located in said burner throat.

25. The burner assembly of claim 22, wherein said flame diverter is a fluid injection assembly associated with said ignition passageway for injecting fluid into said ignition passageway toward said ignition zone.

26. The burner assembly of claim 25, wherein said fluid injection assembly is adapted to be fluidly connected to a source of fuel whereby said fluid injection assembly can inject fuel into said ignition passageway.

27. The burner assembly of claim 18, wherein said exterior surface of said burner tile includes a top section, a bottom section and a sidewall section connecting said top section to said bottom section.

28. The burner assembly of claim 27, wherein said main fuel combustion tip and said ignition zone are located adjacent to said sidewall section of said exterior surface of said burner tile.

29. The burner assembly of claim 28, wherein said fuel injection assembly further includes a supplemental fuel tip and supplemental fuel riser for injecting supplemental fuel into said combustion zone, said supplemental fuel riser having an inlet adapted to be fluidly connected to a source of fuel and an outlet connected to said supplemental fuel tip.

30. The burner assembly of claim 29, wherein said supplemental fuel riser is partially disposed through the burner tile and extends into a trough disposed in the burner tile that includes an outlet positioned adjacent to said combustion zone, and said supplemental fuel tip is disposed in said trough.

31. The burner assembly of claim 18, wherein said burner assembly includes more than one ignition passageway, more than one ignition zone and more than one main fuel combustion tip, said ignition zones and main fuel combustion tips being located adjacent to said sidewall section of said exterior surface of said burner tile.

32. The burner assembly of claim 31 wherein said fuel injection assembly includes more than one supplemental fuel tip, said supplemental fuel tips being positioned to discharge supplemental fuel into said combustion zone. 25

33. The burner assembly of claim 18, further comprising a turning member, said turning member located adjacent to said exterior surface of said burner tile and positioned to redirect said flame or a portion thereof from said outlet of said ignition passageway across said exterior surface.

34. The burner assembly of claim 33, further comprising a stabilizing member, said stabilizing member positioned on said exterior surface of said burner tile to receive said flame or a portion thereof and facilitate contact of said flame or a portion thereof with fuel injected by said main fuel tip.

35. The burner assembly of claim 34, wherein said stabilizing member is attached to said turning member and extends substantially perpendicularly therefrom along said exterior surface of said burner tile, and said stabilizing member receives said flame or a portion thereof from said turning block.

36. A method of using a burner assembly that includes a burner tile and a burner throat extending therethrough to combust fuel in a furnace space in order to generate heat without admixing a significant amount of fuel with combustion air in the burner throat, comprising: conducting combustion air through the burner throat into a combustion zone located within the furnace and adjacent to the exterior surface the burner tile; generating a pilot flame in the burner throat with pilot fuel provided by a burner pilot assembly; injecting essentially all of the fuel needed for operation of the burner assembly into the furnace from one or more fuel tips located outside of the burner throat, the one or more fuel tips including a main fuel tip for injecting main fuel into an ignition zone located within the furnace and adjacent to the exterior surface of the burner tile; igniting main fuel in the ignition zone; and admixing ignited main fuel with combustion air conducted through the burner throat in the combustion zone.

37. The method of claim 36, wherein at least a portion of the pilot flame generated in the burner throat is used to ignite main fuel in the ignition zone.

38. The method of claim 37, wherein the pilot flame or portion thereof is used to ignite main fuel in the ignition zone by conducting the pilot flame or portion thereof into the ignition zone through an ignition passageway extending through the burner tile between the 26 burner throat and the exterior surface of the burner tile whereby the pilot flame or portion thereof can contact and ignite fuel in the injection zone.

39. The method of claim 38, further comprising the step of pre-mixing oxygen with the pilot fuel in the burner pilot assembly prior to generating the pilot flame.

40. The method of claim 39, further comprising the step of diverting the pilot flame or portion thereof into the ignition passageway.

41. The method of claim 38, further comprising diverting a first portion of the pilot flame into the ignition passageway and allowing a second portion of the pilot flame to be conducted through the burner throat into the combustion zone.

42. The method of claim 40, wherein the pilot flame or portion thereof is diverted into the ignition passageway by impinging the pilot flame or portion thereof on a diverting member located in the burner throat.

43. The method of claim 40, wherein the ignition passageway includes a Coanda surface, and the pilot flame or portion thereof is diverted into the ignition passageway by directing the pilot flame or portion thereof on the Coanda surface.

44. The method of claim 40, wherein the pilot flame or portion thereof is diverted into the ignition passageway by causing the pressure in the ignition passageway to be lower than the pressure in the burner throat.

45. The method of claim 44, wherein the pressure in the ignition passageway is caused to be lower than the pressure in the burner throat by injecting an eductor fluid into the ignition passageway toward the ignition zone.

46. The method of claim 45, wherein the eductor fluid is fuel.

47. The method of claim 36 wherein the one or more fuel tips include a supplemental fuel tip for injecting supplemental fuel into the combustion zone, and said method further comprises the step of injecting supplemental fuel into the combustion zone.

48. A method of using a burner assembly that includes a burner tile and a burner throat extending therethrough to combust fuel in a furnace space in order to generate heat, comprising: conducting combustion air through the burner throat into a combustion zone located within the furnace and adjacent to the exterior surface of the burner tile; generating a pilot flame in the burner throat with pilot fuel provided by a burner pilot assembly; 27 injecting fuel into the furnace from one or more fuel tips located outside of the burner throat, the one or more fuel tips including a main fuel tip for injecting main fuel into an ignition zone located within the furnace and adjacent to the exterior surface of the burner tile; conducting at least a portion of the pilot flame from the burner throat to the ignition zone and using said pilot flame or portion thereof to ignite main fuel in the ignition zone; and admixing ignited main fuel with combustion air conducted through the burner throat into the combustion zone.

49. The method of claim 48, wherein the pilot flame or portion thereof is conducted from the burner throat to the ignition zone by conducting the pilot flame or portion thereof through an ignition passageway extending through the burner tile between the burner throat and said exterior surface of the burner tile.

50. The method of claim 48, wherein essentially all of the fuel needed for operation of the burner assembly is injected into the furnace from one or more fuel tips located outside of the burner throat.

51. The method of claim 49, further comprising the step of pre-mixing oxygen with the pilot fuel in the burner pilot assembly prior to generating the pilot flame.

52. The method of claim 49, further comprising the step of diverting the pilot flame or portion thereof into the ignition passageway.

53. The method of claim 49, further comprising diverting a first portion of the pilot flame into the ignition passageway and allowing a second portion of the pilot flame to be conducted through the burner throat into the combustion zone.

54. The method of claim 52, wherein the pilot flame or portion thereof is diverted into the ignition passageway by impinging the pilot flame or portion thereof on a diverting member located in the burner throat.

55. The method of claim 52, wherein the ignition passageway includes a Coanda surface, and the pilot flame or portion thereof is diverted into the ignition passageway by directing the pilot flame or portion thereof on the Coanda surface.

56. The method of claim 52, wherein the pilot flame or portion thereof is diverted into the ignition passageway by causing the pressure in the ignition passageway to be lower than the pressure in the burner throat. 28

57. The method of claim 56, wherein the pressure in the ignition passageway is caused to be lower than the pressure in the burner throat by injecting an eductor fluid into the ignition passageway toward the ignition zone.

58. The method of claim 57, wherein the eductor fluid is fuel.

59. The method of claim 48 wherein the one or more fuel tips include a supplemental fuel tip for injecting supplemental fuel into the combustion zone, and said method further comprises the step of injecting supplemental fuel into the combustion zone.