Furnace Controller and Method of Operating a Furnace

A control scheme for a furnace can use real-time and historical data to model performance and determine relationships between different data and performance parameters for use in correcting suboptimal performance of the furnace in real-time. Operational parameters can be logged throughout the cycle for all cycles for a period of time in order to establish a baseline. This data can then be used to calculate the performance of the process. A regression analysis can be carried out in order to determine which parameters affect different aspects of performance. These relationships can then be used to predict performance during a single cycle in real-time and provide closed or open loop feedback to control furnace operation to result in enhanced performance. 1. A method for controlling operation of a furnace to melt a material that comprises metal , the metal comprising:storing data related to the charge material, furnace condition and operation data for the furnace for a plurality of different cycles of operation of the furnace in a non-transitory computer readable medium of a computer device;creating or determining one or more cycle performance parameters based on the stored data;creating a historian data store based on the stored data parameters and the cycle performance parameters;determining x-variables for the one or more cycles of operation of the furnace and feeding the x-variables into a regression model to determine a relationship between at least one of the x-variables with at least one y-variable to define at least one reference cycle, each y-variable corresponding to a respective one of the cycle performance parameters;receiving real-time data from sensors of the furnace;comparing the real-time data from the sensors of the furnace to the at least one reference cycle to determine whether an adjustment to one or more furnace operational parameters is needed;upon determining that a difference from the at least one reference cycle exists that meets or exceeds a ...

Solid Fuel Burner and Method of Operating

An oxy-gaseous fuel burner ( 400, 500 ) or a solid fuel burner ( 700 ) having an annular cavity ( 404, 504, 704 ) upstream from and proximate to an outlet plane ( 416, 516, 716 ) and a converging ( 434, 734 ) or converging-diverging nozzle ( 537 ) located upstream from and proximal to the cavity ( 404, 504, 704 ). The solid fuel burner ( 700 ) also is preferably operated so that the velocity of gas exiting a second annulus ( 730 ) is less than the velocity of gas exiting a central conduit ( 710 ).

OXYGEN-FUEL BURNER WITH CAVITY-ACTUATED MIXING

An oxy-gaseous fuel burner () or a solid fuel burner () having an annular cavity () upstream from and proximate to an outlet plane () and a converging () or converging-diverging nozzle () located upstream from and proximal to the cavity (). The solid fuel burner () also is preferably operated so that the velocity of gas exiting a second annulus () is less than the velocity of gas exiting a central conduit (). 1. A burner comprising:a first annular conduit in fluid flow communication with a supply of an annular gas, the annular gas comprising one of oxygen and a gaseous fuel, the first annular conduit having a first inner wall and a first outer wall;a central conduit located within the first annular conduit and being in fluid flow communication with a supply of a central gas, the central gas comprising the other of oxygen and a gaseous fuel, the central conduit having a central outer wall and an outlet plane; anda cavity formed in at least one of the central outer wall, the first inner wall, and the first outer wall, the cavity being positioned proximal to and a non-zero distance upstream of the outlet plane of the central conduit, the cavity having a length, a depth, and an aspect ratio defined as the length divided by the depth, the depth being at least 10% of the hydraulic diameter of the conduit bounded by the wall in which the cavity is formed, the aspect ratio being from 1 to 10.2. The burner of claim 1 , wherein the central gas consists of oxygen and the annular gas consists of the gaseous fuel.3. The burner of claim 1 , wherein the central gas consists of the gaseous fuel and the annular gas consists of oxygen.4. The burner of claim 1 , wherein the cavity has an aspect ratio of between 1 and 4.5. The burner of claim 1 , wherein the cavity has an upstream wall claim 1 , a bottom wall claim 1 , and a downstream wall claim 1 , and wherein the length is a distance between the upstream wall and the downstream wall claim 1 , and wherein the depth is a height of one ...

BOTTOM STIRRING TUYERE AND METHOD FOR A BASIC OXYGEN FURNACE

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. 1. A method of operating a bottom stir tuyere in a basic oxygen furnace for steel making , wherein the bottom stir tuyere has a concentric nozzle arrangement with an inner nozzle surrounded by an annular nozzle , the method comprising:(a) during a hot metal pour phase, flowing an inert gas through both nozzles of the bottom stir tuyere;(b) during a blow phase, continuing to flow the inert gas through both nozzles of the bottom stir tuyere;(c) during a tap phase, initiating a flow of a first reactant and ceasing the flow of inert gas through the inner nozzle of the tuyere, and initiating a flow of a second reactant and ceasing the flow of inert gas through the annular nozzle of the tuyere, wherein the first reactant includes one of fuel and oxidant and the second reactant includes the other of fuel and oxidant, such that a flame forms as the fuel and oxidant exit the tuyere;(d) during a slag splash phase, continuing the flows of fuel and oxidant to maintain the flame; and(e) after ending the slag splash phase and commencement of another hot metal pour phase, initiating a flow of inert gas through both nozzles of the bottom stir ...

Sensor Device for Providing Control for a Food Processing System

A processor of a sensor device receives a plurality of images capturing a scene that depicts at least a portion of a conveyer entering a treatment area of a food processing system. The processor processes one or more images, among the plurality of images, to detect one or more characteristics in the scene. Processing the one or more images includes detecting presence or absence of a product on the at least the portion of the conveyor depicted in the scene, and classifying the scene as having one or more characteristics among a predetermined set of characteristics. The sensor device provides characteristics information indicating the one or more characteristics detected in the scene to a controller. The characteristics information is to be used by the controller to control operation of one or both of the conveyor and the treatment area of the food processing system.

System and Method of Operating a Batch Melting Furnace

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. 1. A system for controlling a metals melting process in a batch melting furnace comprising:a melting furnace comprising a chamber configured and arranged to receive a charge containing solid metal, a burner configured and arranged to provide heat of combustion to the charge in the chamber, and a passage to exhaust burner combustion products from the chamber, wherein the melting furnace is characterized by at least one furnace parameter;at least one sensor to detect at least one charge parameter characterizing a charge added to the furnace;at least one sensor to detect at least one process parameter characterizing progress of a melting process in the furnace; and calculate a furnace efficiency based on the at least one furnace parameter;', 'calculate a predicted process pour readiness time based on the at least one charge parameter, the at least one process parameter, and the overall efficiency; and', 'control operation of the furnace based on the predicted process pour readiness time., 'a controller having a processor configured to2. The system of claim 1 , further comprising:at least one sensor to detect at least one output ...

Smart Sensor Measurement System

A first camera captures a first image of a scene, and a second camera captures a second image capturing thermal distribution across the scene. The first image is processed to detect one or more objects of interest in the scene and to identify respective surface characteristics of the objects. The first image is overlaid with the second image to identify regions of interest in the second image corresponding to the objects of interest in the first image. Values of pixels that belong to respective regions of interest in the second image are converted to temperature values using respective conversion functions that reflect respective emissivity values determined by the identified respective surface characteristics of the corresponding objects of interest in the first image. The temperature values are analyzed to monitor thermal conditions of the one or more objects of interest in the scene. 1. A method for processing thermal image data in a sensor device , the method comprising:processing, with a processor of the sensor device, a first image of a scene to detect one or more objects of interest in the scene, wherein detecting the one or more objects of interest includes identifying respective surface characteristics of the one or more objects of interest detected in the scene;overlaying, with the processor of the sensor device, the first image of the scene with a second image of the scene, the second image capturing thermal distribution across the scene, to identify one or more regions of interest in the second image of the scene corresponding to the one or more objects of interest detected in the first image of the scene;converting, with the processor of the sensor device, values of pixels in the one or more regions of interest identified in the second image of the scene to temperature values, including converting values of pixels that belong to respective regions of interest, among the one or more regions of interest in the second image of the scene, using respective ...

Oxygen-fuel burner with cavity-actuated mixing

An oxy-gaseous fuel burner (400, 500) or a solid fuel burner (700) having an annular cavity (404, 504, 704) upstream from and proximate to an outlet plane (416, 516, 716) and a converging (434, 734) or converging-diverging nozzle (537) located upstream from and proximal to the cavity (404, 504, 704). The solid fuel burner (700) also is preferably operated so that the velocity of gas exiting a second annulus (730) is less than the velocity of gas exiting a central conduit (710).

Bottom stirring tuyere and method for operating a basic oxygen furnace

Bottom stirring tuyere and method for a basic oxygen furnace

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.

Solid fuel burner and method of operating

Furnace controller and method of operating a furnace

A control scheme for a furnace can use real-time and historical data to model performance and determine relationships between different data and performance parameters for use in correcting suboptimal performance of the furnace in real-time. Operational parameters can be logged throughout the cycle for all cycles for a period of time in order to establish a baseline. This data can then be used to calculate the performance of the process. A regression analysis can be carried out in order to determine which parameters affect different aspects of performance. These relationships can then be used to predict performance during a single cycle in real-time and provide closed or open loop feedback to control furnace operation to result in enhanced performance.

Furnace controller and method of operating a furnace

A control scheme for a furnace can use real-time and historical data to model performance and determine relationships between different data and performance parameters for use in correcting suboptimal performance of the furnace in real-time. Operational parameters can be logged throughout the cycle for all cycles for a period of time in order to establish a baseline. This data can then be used to calculate the performance of the process. A regression analysis can be carried out in order to determine which parameters affect different aspects of performance. These relationships can then be used to predict performance during a single cycle in real-time and provide closed or open loop feedback to control furnace operation to result in enhanced performance.

Oven controller and method of operating an oven

Um esquema de controle para um forno pode usar dados históricos e em tempo real para modelar o desempenho e determinar relações entre diferentes dados e parâmetros de desempenho para uso na correção de desempenho de forno subótimo em tempo real. Os parâmetros operacionais podem ser registrados ao longo do ciclo para todos os ciclos por um período de tempo a fim de estabelecer uma linha de base. Esses dados podem ser, então, usados para calcular o desempenho do processo. Uma análise de regressão pode ser realizada a fim de determinar quais parâmetros afetam diferentes aspectos do desempenho. Essas relações podem ser, então, usadas para prever o desempenho durante um único ciclo em tempo real e fornecer realimentação de laço fechado ou aberto para controlar a operação do forno, de modo que resulte em um desempenho melhorado. A control scheme for a kiln can use real-time and historical data to model performance and determine relationships between different data and performance parameters for use in correcting real-time suboptimal kiln performance. Operating parameters can be recorded throughout the cycle for all cycles for a period of time to establish a baseline. This data can then be used to calculate process performance. A regression analysis can be performed to determine which parameters affect different aspects of performance. These relationships can then be used to predict performance during a single cycle in real time and provide closed or open loop feedback to control oven operation so that improved performance results.

System and method of operating a batch melting furnace

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.

Ventaneira de agitação de fundo e método para uma fornalha de oxigênio básica

trata-se de um método de operação de uma ventaneira de agitação de fundo de bof que tem um bocal interno circundado por um bocal anelar, incluindo durante uma fase de despejo de metal a quente e uma fase de sopro, fluir um gás inerte através de ambos os bocais; durante uma fase de derivação, iniciar um fluxo de um primeiro reagente através do bocal interno e um fluxo de um segundo reagente através do bocal anelar, e cessar o fluxo de gás inerte através dos bocais, em que o primeiro e o segundo reagentes incluem combustível e oxidante, respectivamente, ou vice-versa, de modo que uma chama se forme à medida que o combustível e o oxidante saem da ventaneira; durante uma fase de borrifo de escória, continuar os fluxos de combustível e oxidante para manter a chama; e após terminar a fase de borrifo de escória e começar uma outra fase de despejo de metal a quente, iniciar um fluxo de gás inerte através de ambos os bocais e cessar os fluxos do primeiro e do segundo reagentes.

Sistema e método de operação de um forno de fusão por batelada

um sistema e método de controle de um processo de fusão de metal em um forno de fusão, que inclui determinar pelo menos um parâmetro do forno que identifique um forno de fusão, adicionando uma carga que contém metal sólido no forno de fusão, detectando pelo menos um parâmetro de carga que identifique a carga, ateando um queimador no forno de fusão para fornecer calor para fundir a carga, e os produtos da combustão de escapamento do forno, detectando pelo menos um parâmetro de processo que identifique o progresso da fusão da carga, calculando uma eficiência do forno com base em pelo menos um parâmetro do forno, calculando um tempo de prontidão de corrida de processo previsto com base em pelo menos um parâmetro de processo, e na eficiência do forno, e controlando o processo de fusão do metal com base no tempo de prontidão de corrida de processo previsto.

Sensor device for providing control for a food processing system

A processor of a sensor device receives a plurality of images capturing a scene that depicts at least a portion of a conveyer entering a treatment area of a food processing system. The processor processes one or more images, among the plurality of images, to detect one or more characteristics in the scene. Processing the one or more images includes detecting presence or absence of a product on the at least the portion of the conveyor depicted in the scene, and classifying the scene as having one or more characteristics among a predetermined set of characteristics. The sensor device provides characteristics information indicating the one or more characteristics detected in the scene to a controller. The characteristics information is to be used by the controller to control operation of one or both of the conveyor and the treatment area of the food processing system.

Sensor device for providing control for a food processing system

A processor of a sensor device receives a plurality of images capturing a scene that depicts at least a portion of a conveyer entering a treatment area of a food processing system. The processor processes one or more images, among the plurality of images, to detect one or more characteristics in the scene. Processing the one or more images includes detecting presence or absence of a product on the at least the portion of the conveyor depicted in the scene, and classifying the scene as having one or more characteristics among a predetermined set of characteristics. The sensor device provides characteristics information indicating the one or more characteristics detected in the scene to a controller. The characteristics information is to be used by the controller to control operation of one or both of the conveyor and the treatment area of the food processing system.

Method of providing control for a food processing system and a sensor device therefor