The report documents the detailed scale-up and design phase of a program to develop a low-NOx burner system that can be retrofitted to an existing thermally enhanced oil recovery (TEOR) steam generator. The emission design goal for the 16 MW commercial grade burner system is to maintain NOx emissions below 85 ppm (at 3 percent O2) while firing a heavy fuel oil containing above 0.6 percent bound nitrogen. The burner system selected to achieve this emission goal utilizes a staged combustion process in which the first stage is thermally isolated and provides long residence time under high temperature, optimally fuel-rich conditions. Results from earlier tests at three scales (21 kW, 0.6 MW, and 3 MW) are compared to identify design parameters for the 16 MW full-scale burner. This comparison shows that residence time and temperature in the first stage are the most important scaling parameters. Detailed thermodynamic/mechanical design features of the full-scale burner hardware are discussed. Initial evaluation of this burner in a test furnace and results from long-term tests in a field operating steam generator are documented in two other volumes.