Burner Device with Primary Air Chamber, Staged Air Chamber, and Tertiary Air Chamber

A process for combusting a fuel in a furnace comprising a furnace enclosure and a burner device, wherein the burner device comprises a primary air chamber, a staged air chamber, a tertiary air chamber, a burner tube having a first tube end and a second tube end, and a burner tip having center orifices and side orifices coupled to the second tube end, a tile in proximity to the burner tip defining a tile-burner tip gap between the tile and the burner tip, the first tube end is in fluid communication with the primary air chamber, the furnace enclosure is in fluid communication with the staged air chamber via one or more staged air ports, the furnace enclosure is in fluid communication with the tertiary air chamber via the tile-burner tip gap, and the process comprises:

• supplying a primary air and a flue gas into the primary air chamber to form an air-flue gas mixture in the primary air chamber;
• supplying a staged air into the staged air chamber;
• supplying a tertiary air into the tertiary air chamber;
• supplying the fuel into the first tube end;
• receiving the air-flue gas mixture via the first tube end into the burner tube to mix with fuel to form a fuel-air-flue gas mixture in the burner tube;
• discharging a first portion of the fuel-air-flue gas mixture into a first combustion zone in the furnace enclosure via the center orifices of the burner tip;
• discharging a second portion of the fuel-air-flue gas mixture into a second combustion zone in the furnace enclosure via the side orifices of the burner tip;
• discharging the tertiary air into the second combustion zone via the tile-burner tip gap;
• discharging the staged air from the staged air chamber into a third combustion zone in the furnace enclosure via the one or more staged air ports;
• and
• combusting the fuel in at least one of the first combustion zone, the second combustion zone, and the third combustion zone.