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: 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 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: A burner retraction system includes a mounting assembly having a mounting sleeve, an insertion assembly having a tubular sleeve including an insertion portion sized and shaped for insertion into the mounting sleeve and an opening therethrough, a pivot rod rigidly mounted to and extending rearwardly from the mounting plate, and a pivot assembly rigidly mounted to the insertion sleeve and including a pivot tube surrounding and coaxially rotatable about the pivot rod, one of the pivot rod and the pivot tube having a slot including a straight axially extending portion and an angled portion extending rearwardly from the straight portion at an angle ?, and a stop pin slidably inserted into the slot in the one of the pivot rod and the pivot tube, the stop pin being secured to the other of the pivot rod and the pivot tube.

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: An oxy-fuel burner (10) with monitoring including a fuel passage (320) terminating in a fuel nozzle (322), a primary oxidant passage (330) terminating in an oxidant nozzle (333), one or more sensors including a nozzle temperature sensor (372) for sensing at least one of an oxidant nozzle temperature and a fuel nozzle temperature, and a data processor (66, 166,266) programmed to receive data from the sensors and to determine based on at least a portion of the received data the presence or absence of an abnormal burner condition including a potential partial obstruction of at least one of the primary oxidant passage (330) and the fuel passage (320) based on an increase or decrease in at least one of the oxidant nozzle temperature and the fuel nozzle temperature.

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: An integrated retractable burner ignition system including a burner having an outlet face and a flow passage including a front end substantially coincident with the outlet face of the burner and a gas inlet positioned rearward from the front end of the flow passage, an igniter including a high voltage electrode surrounded by an insulator and extending beyond the insulator to form a tip end of the igniter, the igniter being mounted slidably within the flow passage, an actuator connected to a rear portion of the igniter and configured to advance and retract the igniter within the flow passage, and a slidable seal between the igniter and the flow passage, the seal being positioned rearward of the gas inlet of the flow passage and frontward of the rear portion of the igniter.

Abstract: A precombustor system to be used in conjunction with an oxy-fuel burner employing recycled flue gas is disclosed. A method of introducing streams into the precombustor to achieve desired improvements in flame properties is also disclosed.

Abstract: An oxy-oil burner with monitoring, including an oil lance having an oil nozzle at a tip end, and an oil inlet distal from the tip end; a primary oxidant passage surrounding the oil lance; an oil nozzle temperature sensor positioned in the oil nozzle at the tip end of the oil lance; an oil inlet temperature sensor positioned near the oil inlet; an oil pressure sensor positioned near the oil inlet passage; and an instrument enclosure for receiving data from the sensors; wherein the oil nozzle temperature, the oil supply temperature, and the oil supply pressure in combination are usable to indicate an abnormal burner condition.

Abstract: A remote burner monitoring system including one or more burners each including integrated sensors, a data collector corresponding to each of the burners for receiving and aggregating data from the sensors of the corresponding burner, and a local transmitter corresponding to each of the data collectors for transmitting the data, a data center configured and programmed to receive the data from the local transmitters corresponding to the one or more burners, and a server configured and programmed to store at least a portion of the data, to convert the data into a display format, and to provide connectivity to enable receipt and transmission of data and the display format via a network including at least one of a wired network, a cellular network, and a Wi-Fi network.

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 burner retraction system includes a mounting assembly having a mounting sleeve, an insertion assembly having a tubular sleeve including an insertion portion sized and shaped for insertion into the mounting sleeve and an opening therethrough, a pivot rod rigidly mounted to and extending rearwardly from the mounting plate, and a pivot assembly rigidly mounted to the insertion sleeve and including a pivot tube surrounding and coaxially rotatable about the pivot rod, one of the pivot rod and the pivot tube having a slot including a straight axially extending portion and an angled portion extending rearwardly from the straight portion at an angle ?, and a stop pin slidably inserted into the slot in the one of the pivot rod and the pivot tube, the stop pin being secured to the other of the pivot rod and the pivot tube.

Abstract: An integrated retractable burner ignition system including a burner having an outlet face and a flow passage including a front end substantially coincident with the outlet face of the burner and a gas inlet positioned rearward from the front end of the flow passage, an igniter including a high voltage electrode surrounded by an insulator and extending beyond the insulator to form a tip end of the igniter, the igniter being mounted slidably within the flow passage, an actuator connected to a rear portion of the igniter and configured to advance and retract the igniter within the flow passage, and a slidable seal between the igniter and the flow passage, the seal being positioned rearward of the gas inlet of the flow passage and frontward of the rear portion of the igniter.

Abstract: A precombustor having a chamber having a first end and a second end, and an inlet configured to deliver a substantially parallel flow of solid fuel surrounded by oxygen at the first end. The first end further includes a recirculation step and the second end fluidly communicates with a furnace. The inlet and the recirculation step are arranged to form a recirculation zone of at least a portion of the solid fuel and the oxygen. A combustion system and method for operating a combustion system are also disclosed.

Abstract: A method of operating a pyrolysis heater for reduced emissions of NOx and carbon monoxide. One or more wall burners, typically premix burners, are operated with more excess oxidant gas than one or more of the floor or hearth burners, which are typically non-premix burners. The invention takes advantage of different NOx emissions characteristics from different types of burners.

Abstract: A method of combustion and a reformer. The method includes combusting a fuel in a combustion region of an up-fired or down-fired reformer and forming non-uniform injection properties with a wall-bound burner. The combusting is performed in a combustion region by burners, wherein at least one of the burners is the wall-bound burner forming the non-uniform injection properties. The non-uniform injection properties generate a heat profile providing a first heat density proximal to a wall and a second heat density distal from the wall, the second heat density being greater than the first heat density. The non-uniform injection properties are formed by injection properties selected from an angle of one or more injectors, a flow rate of one or more injectors, an amount and/or location of oxidant injectors, an amount and/or location of fuel injectors, and combinations thereof.

Abstract: A method of combustion and a reformer. The method includes combusting a fuel in combustion region of an up-fired or down-fired reformer and forming non-uniform injection properties with a wall-bound burner. The combusting is performed in a combustion region by burners, wherein at least one of the burners is the wall-bound burner forming the non-uniform injection properties. The non-uniform injection properties generate a heat profile providing a first heat density proximal to a wall and a second heat density distal from the wall, the second heat density being greater than the first heat density. The non-uniform injection properties are formed by injection properties selected from an angle of one or more injectors, a flow rate of one or more injectors, an amount and/or location of oxidant injectors, an amount and/or location of fuel injectors, and combinations thereof.

Abstract: An oxy/coal combustion system and method include a furnace arranged and disposed to receive and combust a first solid fuel to form a combustion fluid, a convective section having one or more inlet devices, the convective section arranged and disposed to receive and combust a second fuel in the presence of the oxygen, and one or more heat exchangers arranged and disposed to exchange heat with the combustion fluid.