A large diameter mid-zone air separation cone is provided for decreasing NOx during burner operation by expanding the internal recirculation zone (IRZ) at the burner exit. The mid-zone air separation cone has a short cylindrical leading edge that fits in the outer air zone of a burner. The mid-zone air separation cone splits the outer air zone secondary air flow into two equal or unequal streams depending on the position of the air separation cone with respect to the outer air zone, and deflects a portion of the secondary air flow radially outward. Since the radial position of the air separation cone is farther from the burner centerline, the IRZ size is expanded and NOx emissions are minimized.