Abstract: Provided is a method for estimating the impact of fuel distribution on emissions and corrosion responses of a fossil fuel-fired furnace. A variable is determined, termed herein separation number, by inputting fuel oil and air into the furnace, wherein the variable provides a linear relationship to multiple furnace process responses. Emission measurement equipment is located at various furnace outlet positions and thermocouples are located in tubes of the furnace, wherein the responses can be measured to obtain operating data. This operating data is interpreted based on different modes of operation of the furnace, and a change is estimated in the responses as a function of the separation number, wherein the change can be quantified to determine an impact of the fuel distribution or the furnace configuration as a result of the operating data lying on a plane defined by the separation number and a load variable.

Abstract: The present invention is a method for determining the optimum operating practice for an industrial process. The methodology includes a combination of process control steps and data analysis techniques to investigate responses to controlled “black box” process inputs, e.g., coal and air feeds for coal-fired furnaces in the case studies above. A unique time-dependent perturbation is applied to individual process feed streams to give a signature in the data that permits the filtering and detection of various measured responses, e.g., continuous emission monitor readings for NOx, SO2, CO2, CO, and opacity for regulated electric utility furnaces. The perturbation is implemented using the plant control system. Individual control signal set points are perturbed for each piece of equipment supplying process inputs of interest. As a result, complex commercial processes can be evaluated for optimization without changing the normal configuration of the system.

Abstract: A device for optimizing coal-air proportions entering a furnace is disclosed. The invention generally comprises a burner nozzle having two ends and an outer tube forming a perimeter of the burner nozzle; an entry spool having a rear wall and defining an inlet port at one of the ends of the burner nozzle; an inner tube formed within the burner nozzle; an annular blade chamber defined between the outer tube and the inner tube; and, a blade formed within the blade chamber configured as an extension of the rear wall of the entry spool, the blade twisted to form a spiral around the inner tube, wherein fuel particles can be separated from a primary air stream and collected on the blade to form a coal-concentrated stream for entry into the furnace. As a result, three separate streams are injected into the furnace, thereby minimizing NOx through the concentration of solid fuel.

Abstract: Provided is a method for estimating the impact of fuel distribution on emissions and corrosion responses of a fossil fuel-fired furnace. A variable is determined, termed herein separation number, by inputting fuel oil and air into the furnace, wherein the variable provides a linear relationship to multiple furnace process responses. Emission measurement equipment is located at an inlet and outlet of an SCR of the furnace and thermocouples are located in tubes of the furnace, wherein the responses can be measured to obtain operating data. This operating data is interpreted based on different modes of operation of the furnace, and a change is estimated in the responses as a function of the separation number, wherein the change can be quantified to determine an impact of the fuel distribution or the furnace configuration as a result of the operating data lying on a plane defined by the separation number and a load variable.