Abstract: A method of melting a charge in a double-pass tilt rotary furnace having a door, including operating a first burner at a first firing rate, the first burner being mounted in a lower portion of the door and producing a first flame having a length; operating a second burner at a second firing rate, the second burner being mounted in an upper portion of the door and producing a second flame having a length, the second flame being distal from the charge relative to the first flame; in an initial phase when the solids in the charge impede the first flame, controlling the second firing rate to be greater than the first firing rate; and in an later phase after melting of the solids in the charge sufficiently that the first flame is not impeded, controlling the first firing rate to be greater than the second firing rate.

Abstract: A system and method of controlling a metal melting process in a melting furnace, including determining at least one furnace parameter characterizing a melting furnace, adding a charge containing solid metal into the melting furnace, detecting at least one charge parameter characterizing the charge, firing a burner into the melting furnace to provide heat to melt the charge, and exhausting burner combustion products from the furnace, detecting at least one process parameter characterizing progress of melting the charge, calculating a furnace efficiency based on the at least one furnace parameter, calculating a predicted process pour readiness time based on the at least one charge parameter, the at least one process parameter, and the furnace efficiency, and controlling the metal melting process based on the predicted process pour readiness time.

Abstract: A method for preheating metal pellets before charging into a melting furnace, wherein the pellets are transported by a conveyor belt to a chute and discharged from the chute into the melting furnace, the method including heating the pellets by direct flame impingement from two or more banks of burners, wherein the two or more banks of burners comprise an upstream bank of burners and a downstream bank of burners; and controlling the upstream bank of burners to operate oxygen-rich so as to create an oxidizing zone and the downstream bank of burners to operate fuel-rich so as to create a reducing zone.

Abstract: A method of melting a charge in a double-pass tilt rotary furnace having a door, including operating a first burner at a first firing rate, the first burner being mounted in a lower portion of the door and producing a first flame having a length; operating a second burner at a second firing rate, the second burner being mounted in an upper portion of the door and producing a second flame having a length, the second flame being distal from the charge relative to the first flame; in an initial phase when the solids in the charge impede the first flame, controlling the second firing rate to be greater than the first firing rate; and in an later phase after melting of the solids in the charge sufficiently that the first flame is not impeded, controlling the first firing rate to be greater than the second firing rate.

Abstract: A method of operating a BOF bottom stir tuyere having an inner nozzle surrounded by an annular nozzle, including during a hot metal pour phase and a blow phase, flowing an inert gas through both nozzles; during a tap phase, initiating a flow of a first reactant through the inner nozzle and a flow of a second reactant through the annular nozzle, and ceasing the flow of inert gas through the nozzles, wherein the first and second reactants includes fuel and oxidant, respectively, or vice-versa, such that a flame forms as the fuel and oxidant exit the tuyere; during a slag splash phase, continuing the flows of fuel and oxidant to maintain the flame; and after ending the slag splash phase and commencement of another hot metal pour phase, initiating a flow of inert gas through both nozzles and ceasing the flows of the first and second reactants.

Abstract: A system and method of controlling a metal melting process in a melting furnace, including determining at least one furnace parameter characterizing a melting furnace, adding a charge containing solid metal into the melting furnace, detecting at least one charge parameter characterizing the charge, firing a burner into the melting furnace to provide heat to melt the charge, and exhausting burner combustion products from the furnace, detecting at least one process parameter characterizing progress of melting the charge, calculating a furnace efficiency based on the at least one furnace parameter, calculating a predicted process pour readiness time based on the at least one charge parameter, the at least one process parameter, and the furnace efficiency, and controlling the metal melting process based on the predicted process pour readiness time.

Abstract: A method of operating a BOF bottom stir tuyere having an inner nozzle surrounded by an annular nozzle, including during a hot metal pour phase and a blow phase, flowing an inert gas through both nozzles; during a tap phase, initiating a flow of a first reactant through the inner nozzle and a flow of a second reactant through the annular nozzle, and ceasing the flow of inert gas through the nozzles, wherein the first and second reactants includes fuel and oxidant, respectively, or vice-versa, such that a flame forms as the fuel and oxidant exit the tuyere; during a slag splash phase, continuing the flows of fuel and oxidant to maintain the flame; and after ending the slag splash phase and commencement of another hot metal pour phase, initiating a flow of inert gas through both nozzles and ceasing the flows of the first and second reactants.

Abstract: A direct flame impingement system for preheating metal pellets before charging into a melting furnace, wherein the pellets are transported by a conveyor belt to a chute discharging into the melting furnace, including a refractory-lined preheater hood including a chute hood covering the chute and a conveyor hood covering at least a portion of the conveyor belt, the preheater hood having an entrance end through which pellets enter and an exit end through which pellets exit toward the melting furnace, and at least one bank of burners each containing at least one burner disposed in the hood positioned to direct flames into contact with the pellets being transported to preheat the pellets prior to discharge into the melting furnace.

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 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 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: 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 burner including a central oxidant nozzle defining a central axis of the burner, and a plurality of flame holders each having an axis spaced apart from the axis of the burner, each flame holder including a high shape factor nozzle including a nozzle opening having a shape factor from about 10 to about 75, the shape factor being defined as the square of the nozzle perimeter divided by twice the nozzle cross-sectional area, and an annular nozzle surrounding the high shape factor nozzle, wherein the high shape factor nozzle is configured to be supplied with one of a fuel gas and an oxidizer gas, and the annular nozzle is configured to be supplied with the other of a fuel gas and an oxidizer gas.

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: 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 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.