Abstract: A method and system of controlling a melting process of copper in a copper melting furnace including measuring at least one furnace parameter, wherein the at least one furnace parameter includes one or both of a furnace temperature and a furnace exhaust oxygen concentration, calculating a first rate of change of the furnace parameter over a first time period, calculating a second rate of change of the furnace parameter over a second time period at least a portion of which occurs after the first time period, comparing the first rate of change with the second rate of change, and indicating substantial completion of a process phase in the furnace when the second rate of change deviates by a predetermined threshold percentage from the first rate of change.

Abstract: An integrated sensor system for use in a furnace system including a furnace having at least one burner and two or more zones each differently affected by at least one furnace parameter regulating energy input into the furnace, including a first temperature sensor positioned to measure a first temperature in the furnace system, a second temperature sensor positioned to measure a second temperature in the furnace system; and a controller programmed to receive the first and second measured temperatures, and to adjust operation of a furnace system parameter based on a relationship between the first and second temperatures, thereby differentially regulating energy input into at least two of the zones of the furnace; wherein the relationship between the first and second temperatures is a function of one or more of a difference between the two temperatures, a ratio of the two temperatures, and a weighted average of the two temperatures.

Abstract: An oxy-gaseous fuel burner (400, 500) or a solid fuel burner (700) having an annular cavity (404, 504, 704) upstream from and proximate to an outlet plane (416, 516, 716) and a converging (434, 734) or converging-diverging nozzle (537) located upstream from and proximal to the cavity (404, 504, 704). The solid fuel burner (700) also is preferably operated so that the velocity of gas exiting a second annulus (730) is less than the velocity of gas exiting a central conduit (710).

Abstract: An oxy-gaseous fuel burner (400, 500) or a solid fuel burner (700) having an annular cavity (404, 504, 704) upstream from and proximate to an outlet plane (416, 516, 716) and a converging (434, 734) or converging-diverging nozzle (537) located upstream from and proximal to the cavity (404, 504, 704). The solid fuel burner (700) also is preferably operated so that the velocity of gas exiting a second annulus (730) is less than the velocity of gas exiting a central conduit (710).

Abstract: A selective oxy-fuel burner for mounting in a charge door of a rotary furnace, including at least two burner elements each oriented to fire into different portions of the furnace, each burner element including a selective distribution nozzle configured to flow a first reactant; and a proportional distribution nozzle configured to flow a second reactant; at least one sensor to detect one or more process parameters related to furnace operation; and a controller programmed to independently control the first reactant flow to each selective distribution nozzle based on the detected process parameters such that at least one burner element is active and at least one burner element is passive; wherein the second reactant is substantially proportionally distributed to the proportional distribution nozzles; and wherein the first reactant is one of a fuel and an oxidant and wherein the second reactant is the other of a fuel and an oxidant.

Abstract: An oxy-fuel boost burner for a regenerative furnace having a pair of regenerator ports configured to alternately fire into and exhaust from the furnace, including at least one burner element corresponding to each of the regenerator ports by being positioned to fire into a complimentary region of the furnace, each burner element including a selective distribution nozzle configured to flow a first reactant and a proportional distribution nozzle configured to flow a second reactant, and a controller programmed to identify which regenerator port is currently firing and which is currently exhausting and to independently control the first reactant flow to each selective distribution nozzle such that the at least one burner element corresponding to the currently firing regenerator port has a greater than average first reactant flow and the at least one burner element corresponding to the currently exhausting regenerator port as a less than average first reactant flow.

Abstract: A method and system of controlling a melting process of copper in a copper melting furnace including measuring at least one furnace parameter, wherein the at least one furnace parameter includes one or both of a furnace temperature and a furnace exhaust oxygen concentration, calculating a first rate of change of the furnace parameter over a first time period, calculating a second rate of change of the furnace parameter over a second time period at least a portion of which occurs after the first time period, comparing the first rate of change with the second rate of change, and indicating substantial completion of a process phase in the furnace when the second rate of change deviates by a predetermined threshold percentage from the first rate of change.

Abstract: An oxy-fuel boost burner for a regenerative furnace having a pair of regenerator ports configured to alternately fire into and exhaust from the furnace, including at least one burner element corresponding to each of the regenerator ports by being positioned to fire into a complimentary region of the furnace, each burner element including a selective distribution nozzle configured to flow a first reactant and a proportional distribution nozzle configured to flow a second reactant, and a controller programmed to identify which regenerator port is currently firing and which is currently exhausting and to independently control the first reactant flow to each selective distribution nozzle such that the at least one burner element corresponding to the currently firing regenerator port has a greater than average first reactant flow and the at least one burner element corresponding to the currently exhausting regenerator port as a less than average first reactant flow.

Abstract: A selective oxy-fuel burner for mounting in a charge door of a rotary furnace, including at least two burner elements each oriented to fire into different portions of the furnace, each burner element including a selective distribution nozzle configured to flow a first reactant; and a proportional distribution nozzle configured to flow a second reactant; at least one sensor to detect one or more process parameters related to furnace operation; and a controller programmed to independently control the first reactant flow to each selective distribution nozzle based on the detected process parameters such that at least one burner element is active and at least one burner element is passive; wherein the second reactant is substantially proportionally distributed to the proportional distribution nozzles; and wherein the first reactant is one of a fuel and an oxidant and wherein the second reactant is the other of a fuel and an oxidant.

Abstract: A transient heating burner including at least two burner elements each including a distribution nozzle configured to flow a first fluid and an annular nozzle surrounding the distribution nozzle and configured to flow a second fluid, the burner also including a controller programmed to independently control the flow of the first fluid to each distribution nozzle such that at least one of the distribution nozzles is active and at least one of the distribution nozzles is passive, wherein flow in an active distribution nozzle is greater than an average flow to the distribution nozzles and flow in a passive distribution nozzle is less than the average flow to the distribution nozzles, wherein the first fluid contains a reactant that is one of fuel and oxidant and the second fluid contains a reactant that is the other of fuel and oxidant.

Abstract: A transient heating burner including at least two burner elements each having a distribution nozzle configured to flow a fuel, and an annular nozzle surrounding the distribution nozzle and configured to flow an first oxidant, at least one staging nozzle configured to flow a second oxidant, and a controller programmed to independently control the fuel flow to each distribution nozzle such that at least one of the distribution nozzles is active and at least one of the distribution nozzles is passive, wherein an active distribution nozzle fuel flow is greater than an average fuel flow to the distribution nozzles and a passive nozzle fuel flow is less than the average fuel flow, and to control a staging ratio to be less than or equal to about 75%.

Abstract: A transient heating burner including at least two burner elements each having a distribution nozzle configured to flow a fuel, and an annular nozzle surrounding the distribution nozzle and configured to flow an first oxidant, at least one staging nozzle configured to flow a second oxidant, and a controller programmed to independently control the fuel flow to each distribution nozzle such that at least one of the distribution nozzles is active and at least one of the distribution nozzles is passive, wherein an active distribution nozzle fuel flow is greater than an average fuel flow to the distribution nozzles and a passive nozzle fuel flow is less than the average fuel flow, and to control a staging ratio to be less than or equal to about 75%.