Abstract: A combustion optimization system is disclosed. The system includes a boiler having a plurality of zonal locations, a sensor grid comprising a plurality of sensors, a sensor validation device and an optimizing controller. The plurality of sensors are configured to provide a plurality of sensor signals and the plurality of sensor signals are indicative of measurements of the respective zonal locations. The sensor validation device is configured for receiving the plurality of sensor signals from the plurality of sensors and generating validated sensor signals of the respective sensors based on the plurality of received sensor signals and pre-determined correlations among the plurality of received sensor signals. The optimizing controller is configured for optimizing at least one operating parameter of the boiler based on the validated sensor signals of the respective sensors. A combustion optimization method is also disclosed.

Abstract: An improved gas flow injector has been developed for use in a combustion system. The gas flow injector has an inner nozzle with tubular configuration for directing a first gas stream to a location distal to the gas flow injector. The inner nozzle has an outlet end portion and a longitudinal central axis. Disposed about the inner nozzle is an outer nozzle having a tubular configuration, for directing a second gas stream to a location proximal to the gas flow injector. A diverter is mounted to the outlet end portion of the inner nozzle and extends at least partially into the second gas stream. The diverter has a surface disposed at an acute angle relative to the longitudinal central axis of the inner nozzle to redirect at least a portion of the second gas stream in a direction transverse to the longitudinal central axis. Also disclosed is a method of injecting a gas into a combustion system using the gas flow injector of this invention.

Abstract: A mixing method insures adequate mixing of gases in a glass furnace that employs a reburning process. Because of the mixing method, a novel glass furnace can be constructed that strikes an optimum balance between a reduction in nitrogen oxide (NO.sub.x) emissions and the cost of the reburn process, particularly, the number of requisite reburn and overfire air jets as well as reburn fuel. The glass furnace is constructed as follows. A combustion housing defines a primary zone for receiving combustible fuel, a reburn zone connected to the primary zone for receiving exhaust from the primary zone and reburn fuel to generate a first gas mixture. A burnout zone is connected to the reburn zone and receives the first gas mixture and overfire air to generate a second gas mixture.

Abstract: In a method of this invention, a first oxidant flow including oxygen and/or air, is injected into an exhaust gas flow from a primary burn zone in a furnace combustion chamber. The first oxidant flow is injected into the exhaust gas flow in a secondary burn zone downstream from the primary burn zone, but inside of the furnace chamber so that heat released from combustion of the first oxidant flow can be used for the purpose to which the furnace is applied. Also, the injection of the first oxidant flow into the secondary burn zone combusts fuel pollutants that might otherwise be released from the furnace into the atmosphere. The method can also include mixing a gaseous hydrocarbon fuel flow with the exhaust gas flow from the secondary burn zone to reduce the NO.sub.x, level in the exhaust gas. Also, the method can include mixing a second oxidant flow including air and/or oxygen, with the exhaust gas, preferably after reducing the NO.sub.x.