Abstract: A system for automated control of an industrial process system, comprising: a data historian storing measured process data sensed by a plurality of sensors within the industrial process system; a processor; and, memory storing a control engine as computer readable instructions that, when executed by the processor, cause the processor to: receive an artificial intelligence control setpoint for controlling an operating condition of the industrial process system; compare the artificial intelligence control setpoint to a static threshold and a dynamic threshold; and output a control signal, to manipulate the operating condition, as one of the artificial intelligence control setpoint, the static threshold, or the dynamic threshold based on a relationship of the artificial intelligence control setpoint to the static threshold or dynamic threshold.

Abstract: Systems and methods analyze combustion system operation by predicting an operating parameter based on a portion of measured process data. The predicted operating parameter is associated with a prediction confidence region that is based on hardware uncertainty and historical uncertainty. The historical uncertainty defines drift of the variables used to predict the operating parameter as compared to historical distribution of the values of the variables. The combustion system operation may also be analyzed by comparing a predicted operating parameter against a measured operating parameter, and using the comparison to match to an anomaly solutions database.

Abstract: Emissions of NOX and/or CO are reduced at the stack by systems and methods wherein a primary fuel is thoroughly mixed with a specific range of excess combustion air. The primary fuel-air mixture is then discharged and anchored within a combustion chamber of a burner. Further, the systems and methods provide for dynamically controlling NOX content in emissions from a furnace by adjusting the flow of primary fuel and of a secondary stage fuel, and in some cases controlling the amount or placement of combustion air into the furnace.

Abstract: Systems and methods operate to infer a fuel composition in a combustion system. The fuel composition may be inferred by receiving measured operating parameters including one or more of fuel data defining fuel characteristics used in combustion within a heater of the combustion system, emissions data defining emission gasses exiting the heater, airflow data defining ambient air being supplied to the heater and airflow rate of the air within the heater. One or more relationships within the measured operating parameters may be identified that result in a list of potential fuel compositions. One of the potential fuel compositions from the list may be selected having sufficient likelihood of resulting in the measured operating parameters as an inferred fuel composition. The output the inferred fuel composition to a heater controller of the combustion system and used for automatic control thereof.

Abstract: Combustion heater control systems and methods that include dynamic safety settings. Current operating parameters of the combustion heater are sensed at a plurality of time intervals and converted into a time-varying signal. The time-varying signal is compared to a burner stability envelope indicating when a burner is likely to enter an unstable state. The unstable state may include huffing, flashback, and/or liftoff. When the burner is likely to enter an unstable state, the combustion heater is controlled to prevent the unstable state.

Abstract: Emissions of NOX and/or CO are reduced at the stack by systems and methods wherein a primary fuel is thoroughly mixed with a specific range of excess combustion air. The primary fuel-air mixture is then discharged and anchored within a combustion chamber of a burner. Further, the systems and methods provide for dynamically controlling NOX content in emissions from a furnace by adjusting the flow of primary fuel and of a secondary stage fuel, and in some cases controlling the amount or placement of combustion air into the furnace.

Abstract: Emissions of NOX and/or CO are reduced at the stack by systems and methods wherein a primary fuel is thoroughly mixed with a specific range of excess combustion air. The primary fuel-air mixture is then discharged and anchored within a combustion chamber of a burner. Further, the systems and methods provide for dynamically controlling NOX content in emissions from a furnace by adjusting the flow of primary fuel and of a secondary stage fuel, and in some cases controlling the amount or placement of combustion air into the furnace.

Abstract: Systems and methods operate to infer a fuel composition in a combustion system. The fuel composition may be inferred by receiving measured operating parameters including one or more of fuel data defining fuel characteristics used in combustion within a heater of the combustion system, emissions data defining emission gasses exiting the heater, airflow data defining ambient air being supplied to the heater and airflow rate of the air within the heater. One or more relationships within the measured operating parameters may be identified that result in a list of potential fuel compositions. One of the potential fuel compositions from the list may be selected having sufficient likelihood of resulting in the measured operating parameters as an inferred fuel composition. The output the inferred fuel composition to a heater controller of the combustion system and used for automatic control thereof.

Abstract: Combustion heater control systems and methods that include dynamic safety settings. Current operating parameters of the combustion heater are sensed at a plurality of time intervals and converted into a time-varying signal. The time-varying signal is compared to a burner stability envelope indicating when a burner is likely to enter an unstable state. The unstable state may include huffing, flashback, and/or liftoff. When the burner is likely to enter an unstable state, the combustion heater is controlled to prevent the unstable state.

Abstract: Systems and methods for determining operating discrepancy a process heater. The discrepancy may be identified by solving a fired-systems model of the heater. The fired-systems model is then compared to current operating data. If the sensed current operating data is outside of the expected value(s), as defined by the fired-systems model, the systems and methods may take a remediation action to resolve the discrepancy. The discrepancy may include convection fouling identification and identification of tramp-air leaks within the process heater that are otherwise not easily detected by a human operator.

Abstract: Systems and methods iteratively solve a fired-systems model of the process heater based on fuel information, a target heat release of the plurality of burners, ambient air information, and available airflow at each of the plurality of burners to identify optimized burner air register settings to achieve a target global excess oxygen level to be sensed by the oxygen sensor. The optimized burner air register settings may be output to a heater controller of the process heater for control of the process heater.

Abstract: Emissions of NOx and/or CO are reduced at the stack by systems and methods wherein a primary fuel is thoroughly mixed with a specific range of excess combustion air. The primary fuel-air mixture is then discharged and anchored within a combustion chamber of a burner. Further, the systems and methods provide for dynamically controlling NOx content in emissions from a furnace by adjusting the flow of primary fuel and of a secondary stage fuel, and in some cases controlling the amount or placement of combustion air into the furnace.