U.S. patent application number 16/365807 was filed with the patent office on 2019-07-18 for burner with monitoring.
This patent application is currently assigned to Air Products and Chemicals, Inc.. The applicant listed for this patent is Air Products and Chemicals, Inc.. Invention is credited to Christopher Michael Albright, Mark Daniel D'Agostini, Michael J. Gallagher, Tunc Goruney, Reed Jacob Hendershot, Thomas David Matthew Lee, Aleksandar Georgi Slavejkov.
Application Number | 20190219263 16/365807 |
Document ID | / |
Family ID | 53277023 |
Filed Date | 2019-07-18 |
View All Diagrams
United States Patent
Application |
20190219263 |
Kind Code |
A1 |
Albright; Christopher Michael ;
et al. |
July 18, 2019 |
Burner with Monitoring
Abstract
An oxy-fuel burner with monitoring including a fuel passage
terminating in a fuel nozzle, a primary oxidant passage terminating
in an oxidant nozzle, one or more sensors including a nozzle
temperature sensor for sensing at least one of an oxidant nozzle
temperature and a fuel nozzle temperature and a position sensor for
sensing a burner installation angle, and a data processor
programmed to receive data from the sensors and to determine the
presence or absence of an abnormal burner condition including a
potential partial obstruction of at least one of the primary
oxidant passage and the fuel passage based on an increase or
decrease in at least one of the oxidant nozzle temperature and the
fuel nozzle temperature, and to determine whether the burner is
installed at a desired orientation with respect to at least one
feature of the furnace based on the burner installation angle.
Inventors: |
Albright; Christopher Michael;
(Allentown, PA) ; Hendershot; Reed Jacob;
(Orefield, PA) ; Gallagher; Michael J.;
(Coopersburg, PA) ; Lee; Thomas David Matthew;
(Basingstoke, GB) ; Slavejkov; Aleksandar Georgi;
(Allentown, PA) ; D'Agostini; Mark Daniel;
(Allentown, PA) ; Goruney; Tunc; (Gebze-Kocaeli,
TR) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Air Products and Chemicals, Inc. |
Allentown |
PA |
US |
|
|
Assignee: |
Air Products and Chemicals,
Inc.
Allentown
PA
|
Family ID: |
53277023 |
Appl. No.: |
16/365807 |
Filed: |
March 27, 2019 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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15026309 |
Mar 31, 2016 |
10295184 |
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PCT/US2015/028284 |
Apr 29, 2015 |
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16365807 |
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61987653 |
May 2, 2014 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
F23N 2225/16 20200101;
F23D 14/32 20130101; F23L 7/007 20130101; Y02E 20/34 20130101; F23N
5/022 20130101; F23N 5/242 20130101; Y02E 20/344 20130101; F23N
1/022 20130101 |
International
Class: |
F23N 1/02 20060101
F23N001/02; F23N 5/24 20060101 F23N005/24; F23N 5/02 20060101
F23N005/02; F23L 7/00 20060101 F23L007/00; F23D 14/32 20060101
F23D014/32 |
Claims
1. An oxy-fuel burner with monitoring, comprising: a fuel passage
terminating in a fuel nozzle; a primary oxidant passage terminating
in an oxidant nozzle; one or more sensors including: a nozzle
temperature sensor for sensing at least one of an oxidant nozzle
temperature and a fuel nozzle temperature; and a position sensor
for sensing a burner installation angle, the position sensor being
configured to sense one or more of a burner pitch and a burner
roll; and a data processor programmed to receive data from the
sensors and to determine based on at least a portion of the
received data the presence or absence of an abnormal burner
condition including a potential partial obstruction of at least one
of the primary oxidant passage and the fuel passage based on an
increase or decrease in at least one of the oxidant nozzle
temperature and the fuel nozzle temperature, and to determine
whether the burner is installed at a desired orientation with
respect to at least one feature of the furnace based on the burner
installation angle.
2. The burner with monitoring of claim 1, wherein the data
processor is programmed to base its determination at least in part
upon changes in at least a portion of the received data with
time.
3. The burner with monitoring of claim 1, the one or more sensors
further including an oxidant pressure sensor positioned in the
primary oxidant passage for sensing a primary oxidant pressure;
wherein the data processor is programmed to identify a potential
partial obstruction of the primary oxidant passage based on a
change to the primary oxidant pressure and at least one of the fuel
nozzle temperature and the oxidant nozzle temperature.
4. The burner with monitoring of claim 1, further comprising: a
secondary oxidant passage spaced apart at a fixed distance from the
primary oxidant passage; and a staging valve for proportioning
oxidant between the primary and secondary oxidant passages; the one
or more sensors further including a staging valve position sensor
for sensing a staging valve position as indicative of the relative
proportion of oxidant being directed to the primary and secondary
oxidant passages; wherein the data processor is further programmed
to determine the presence or absence of a partial obstruction of
the primary oxidant passage based on the staging valve position and
at least one of the fuel nozzle temperature and the oxidant nozzle
temperature.
5. The burner with monitoring of claim 1, further comprising: a
secondary oxidant passage spaced apart at a fixed distance from the
primary oxidant passage; and a staging valve for proportioning
oxidant between the primary and secondary oxidant passages; the one
or more sensors further including: an oxidant pressure sensor for
sensing an oxidant pressure at one or more of upstream of the
staging valve, downstream of the staging valve in the primary
oxidant passage, and downstream of the staging valve in the
secondary oxidant passage; and a staging valve position sensor for
sensing a staging valve position as indicative of the relative
proportion of oxidant being directed to the primary and secondary
oxidant passages; wherein the data processor is further programmed
to determine the presence or absence of one or more of a partial
obstruction of one of the primary oxidant passage and the secondary
oxidant passage and a sub-optimal staging valve position based on
the staging valve position and the oxidant pressure at one or more
of upstream of the staging valve, downstream of the staging valve
in the primary oxidant passage, and downstream of the staging valve
in the secondary oxidant passage.
6. The burner with monitoring of claim 5, further comprising: two
pressure sensors, one positioned on either side of a flow
restriction device in at least one of the fuel passage, the primary
oxidant passage, and the secondary oxidant passage, for sensing a
pressure upstream of the flow restriction device, a pressure
downstream of the flow restriction device, and a differential
pressure across the flow restriction device as indicative of flow
rate; wherein the data processor is further programmed to determine
the presence or absence of an abnormal burner condition based on
the differential pressure and one of the pressures upstream and
downstream of the flow restriction device.
7. The burner with monitoring of claim 1, further comprising: a
burner block having a hot face adjacent to the furnace; and a
burner block temperature sensor for sensing a burner block
temperature near the hot face; wherein the data processor is
further programmed to determine the presence or absence of one or
more of burner block overheating and flame asymmetry based on the
burner block temperature.
8. The burner with monitoring of claim 1, further comprising: a
data collector programmed to provide power to individual sensors
only when data is to be collected, based on one or both of a
combination of sensed data and a periodic schedule, and taking into
account the specific requirements of each of the individual
sensors; a transmitter for wirelessly transmitting sensor data from
the data collector to the data processor; and a local power
generation system for powering the data collector, the sensors, and
the transmitter.
9. The burner with monitoring of claim 1, wherein the oxidant
passage is annular and surrounds the fuel passage.
10. A method of determining an operating condition of an oxy-fuel
burner including a fuel passage terminating in a fuel nozzle, a
primary oxidant passage terminating in an oxidant nozzle, and a
burner block having a face adjacent to the furnace, the method
comprising: sensing at least one of an oxidant nozzle temperature
and a fuel nozzle temperature; sensing a burner installation angle
indicative of one or more of a burner pitch and a burner roll;
comparing the at least one nozzle temperature to a threshold
temperature; determining a potential partial obstruction of one of
the oxidant nozzle and fuel nozzle based on an increase or decrease
in the at least one nozzle temperature; and determining whether the
burner is installed at a desired orientation with respect to at
least one feature of the furnace based on the burner installation
angle.
11. The method of claim 10, further comprising: sensing an oxidant
pressure; determining a potential partial obstruction of the
oxidant nozzle based on the oxidant pressure and the at least one
nozzle temperature.
12. The method of claim 10, the burner further including a
secondary oxidant passage spaced apart at a fixed distance from the
primary oxidant passage and a staging valve for proportioning
oxidant between the primary and secondary oxidant passages, the
method further comprising: sensing an oxidant pressure at a
location selected from upstream of the staging valve, downstream of
the staging valve in the primary oxidant passage, and downstream of
the staging valve in the secondary oxidant passage; sensing a
staging valve position indicating the proportion of oxidant being
directed to the primary and secondary oxidant passages; determining
one or more of a potential partial obstruction of one of the
primary oxidant passage and the secondary oxidant passage and a
sub-optimal staging valve position based on the staging valve
position and the oxidant pressure at one or more of upstream of the
staging valve, downstream of the staging valve in the primary
oxidant passage, and downstream of the staging valve in the
secondary oxidant passage.
13. The method of claim 12, further comprising: sensing pressures
at two locations, one on either side of a flow restriction device
in at least one of the fuel passage, the primary oxidant passage,
and the secondary oxidant passage; determining a flow rate from the
pressures at the two locations; and determining the presence or
absence of an abnormal burner condition based on the flow rate and
the pressure of at least one of the two locations.
14. An oxy-fuel burner with monitoring, comprising: a primary first
reactant passage terminating in a first reactant nozzle; a primary
second reactant passage terminating in a second reactant nozzle;
one or more sensors including a nozzle temperature sensor for
sensing a nozzle temperature of at least one of the reactant
nozzles; a position sensor for sensing a burner installation angle,
the position sensor being configured to sense one or more of a
burner pitch and a burner roll; and a data processor programmed to
receive data from the sensors and to determine based on at least a
portion of the received data the presence or absence of an abnormal
burner condition including a potential partial obstruction of at
least one of the primary first reactant passage and the primary
second reactant passage based on an increase or decrease in the at
least one nozzle temperature, and to determine whether the burner
is installed at a desired orientation with respect to at least one
feature of the furnace based on the burner installation angle;
wherein one of the first and second reactants is fuel and the other
of the first and second reactants is oxidant.
15. The burner with monitoring of claim 14, the one or more sensors
further including a first reactant pressure sensor positioned in
the primary first reactant passage for sensing a primary first
reactant pressure; wherein the data processor is programmed to
identify a potential partial obstruction of the primary first
reactant passage based on a change to the first reactant pressure
and the at least one nozzle temperature.
16. The burner with monitoring of claim 14, further comprising: a
secondary first reactant passage spaced apart at a fixed distance
from the primary first reactant passage; and a staging valve for
proportioning the first reactant between the primary and secondary
first reactant passages; the one or more sensors further including
a staging valve position sensor for sensing a staging valve
position as indicative of the relative proportion of the first
reactant being directed to the primary and secondary first reactant
passages; wherein the data processor is further programmed to
determine the presence or absence of a partial obstruction of the
primary first reactant passage based on the staging valve position
and the at least one nozzle temperature.
17. The burner with monitoring of claim 14, further comprising: a
secondary first reactant passage spaced apart at a fixed distance
from the primary first reactant passage; and a staging valve for
proportioning the first reactant between the primary and secondary
first reactant passages; the one or more sensors further including:
a first reactant pressure sensor for sensing a first reactant
pressure at one or more of upstream of the staging valve,
downstream of the staging valve in the primary first reactant
passage, and downstream of the staging valve in the secondary first
reactant passage; and a staging valve position sensor for sensing a
staging valve position as indicative of the relative proportion of
the first reactant being directed to the primary and secondary
first passages; wherein the data processor is further programmed to
determine the presence or absence of one or more of a partial
obstruction of one of the primary first reactant passage and the
secondary first reactant passage and a sub-optimal staging valve
position based on the staging valve position and the first reactant
pressure at one or more of upstream of the staging valve,
downstream of the staging valve in the primary first reactant
passage, and downstream of the staging valve in the secondary first
reactant passage.
18. The burner with monitoring of any of claim 14, further
comprising: a burner block having a hot face adjacent to the
furnace; and a burner block temperature sensor for sensing a burner
block temperature near the hot face; wherein the data processor is
further programmed to determine the presence or absence of one or
more of burner block overheating and flame asymmetry based on the
burner block temperature.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of U.S. application Ser.
No. 15/026,309 filed on Mar. 31, 2016, which was a National Stage
entry of PCT/US2015/028284 filed on Apr. 29, 2015, which claims the
priority of U.S. Provisional Application No. 61/987,652 filed on
May 2, 2014, each of which is incorporated by reference herein in
its entirety.
BACKGROUND
[0002] This application relates to an oxy-fuel burner, and in
particular a staged oxy-fuel burner, configured with
instrumentation to monitor the status and health of the burner, as
well as burner operation and its effect on the process, to perform
real-time control of burner operation based on data obtained from
such monitoring, and to enable intelligent preventative maintenance
to be conducted no sooner than necessary but prior to a failure or
unforeseen shutdown condition.
[0003] For conventional burner systems, furnace operators determine
a maintenance schedule on past experience, or on a regular calendar
basis. This frequently results in a maintenance schedule that is
overly aggressive, costing excess man hours and burner downtime, or
is overly lax, failing to capture correctable burner issues before
a failure occurs.
[0004] Systems exist for limited monitoring of various burner
parameters, but none integrates this monitoring in a comprehensive
way to enable predictive maintenance. For example, some existing
systems require optical access of a flame, temperature sensors to
prevent overheating, or pressure sensors to monitor flame
instability. But none monitor combinations of parameters in a way
that enables predictive maintenance.
SUMMARY
[0005] An oxy-fuel burner, and in some embodiments a staged
oxy-fuel burner, as described herein is configured with integrated
sensors to measure several parameters that are useful in monitoring
the health of the burner and in predicting the need for
maintenance. For any oxy-fuel burner, these parameters may include,
without limitation, separately or in combination, the inlet fuel
pressure, temperature, and density, the inlet oxidant pressure,
temperature, and density, the staging valve position (for a staged
burner), the fuel nozzle temperature, the oxygen nozzle
temperature, burner block temperatures at various locations, one or
more installation angles of the burner and/or burner block, the
relative and/or absolute position of the burner with respect to
other features of the furnace, charge or bath temperatures, and
optical emissions from the flame or the burner face. For a staged
oxy-oil burner, those parameters may include one or more
parameters, separately or in combination, including but not limited
to the inlet oil temperature, the inlet oil pressure, the atomizing
oxidant (air or oxygen-enriched air or oxygen) pressure, the oxygen
feed pressure, the staging valve position, the lance tip or
atomizing nozzle temperature, and the burner block temperature.
This information collected from these sensors can be used by
operators/engineers directly, or by an automated monitoring and
alerting system, to monitor the performance of the burner, to
identify any maintenance needs of the burner, for example to
schedule maintenance and improve the burner operation, and to
detect burner system malfunctions.
[0006] Such instrumentation can be integrated into any burner,
including a burner that uses one or more of gaseous fuel, liquid
fuel, and solid fuel, and including a non-staged burner, a
fuel-staged burner, an oxidant-staged burner, and a burner in which
both fuel and oxidant are staged. It is understood that for each
type of burner, the type, position, and quantity of sensors can be
customized to correspond to the operational modes and parameters
most relevant to that particular burner.
[0007] Various features are built into the burner so that the
electronic monitoring does not interfere with normal operation and
maintenance of the burner. The instrumentation is also protected so
that it will continue to function for long periods of time in the
type of harsh environments in which burners normally operate. In
one embodiment, the electronics are battery powered and transmit
data wirelessly for ease of installation and maintenance.
[0008] A burner with integrated sensors can be used as part of a
system for remote tracking of burner parameters to enable real-time
monitoring of burner performance and to assist in predictive
maintenance by detecting changes in operation of the burner before
a failure or shutdown occurs, such as is described in commonly
owned U.S. patent application Ser. No. 14/268,655 entitled "Remote
Burner Monitoring System and Method" filed May 2, 2014, which is
incorporated by reference herein in its entirety.
[0009] Aspect 1: An oxy-fuel burner with monitoring, comprising: a
fuel passage terminating in a fuel nozzle; a primary oxidant
passage terminating in an oxidant nozzle; one or more sensors for
sensing process data including a nozzle temperature sensor for
sensing at least one of an oxidant nozzle temperature and a fuel
nozzle temperature; and a data processor programmed to receive
process data from the sensors and to determine based on at least a
portion of the received data the presence or absence of an abnormal
burner condition.
[0010] Aspect 2: The burner with monitoring of Aspect 1, wherein
the data processor is programmed to identify a potential partial
obstruction of at least one of the primary oxidant passage and the
fuel passage based on an increase or decrease in at least one of
the oxidant nozzle temperature and the fuel nozzle temperature.
[0011] Aspect 2a: The burner with monitoring of Aspect 2, wherein
the one or more sensor is an oxidant nozzle temperature sensor for
sensing the oxidant nozzle temperature, and wherein the data
processor is programmed to identify a potential partial obstruction
of the primary oxidant passage based on an increase or decrease in
the oxidant nozzle temperature.
[0012] Aspect 2b: The burner with monitoring of Aspect 2, wherein
the one or more sensor is a fuel nozzle temperature sensor for
sensing the fuel nozzle temperature, and wherein the data processor
is programmed to identify a potential partial obstruction of the
fuel passage based on an increase or decrease in the fuel nozzle
temperature.
[0013] Aspect 3: The burner with monitoring of Aspect 1 to 2b,
wherein the data processor is programmed to base its determination
at least in part upon changes in at least a portion of the received
data with time.
[0014] Aspect 4: The burner with monitoring of any of Aspects 1 to
3, the one or more sensors further including an oxidant pressure
sensor positioned in the primary oxidant passage for sensing a
primary oxidant pressure; wherein the data processor is programmed
to identify a potential partial obstruction of the primary oxidant
passage based on a change to the primary oxidant pressure and at
least one of the fuel nozzle temperature and the oxidant nozzle
temperature.
[0015] Aspect 5: The burner with monitoring of any of Aspects 1 to
3, further comprising: a secondary oxidant passage spaced apart at
a fixed distance from the primary oxidant passage; and a staging
valve for proportioning oxidant between the primary and secondary
oxidant passages; the one or more sensors further including a
staging valve position sensor for sensing a staging valve position
as indicative of the relative proportion of oxidant being directed
to the primary and secondary oxidant passages; wherein the data
processor is further programmed to determine the presence or
absence of a partial obstruction of the primary oxidant passage
based on the staging valve position and at least one of the fuel
nozzle temperature and the oxidant nozzle temperature.
[0016] Aspect 6: The burner with monitoring of any of Aspects 1 to
3, further comprising: a secondary oxidant passage spaced apart at
a fixed distance from the primary oxidant passage; and a staging
valve for proportioning oxidant between the primary and secondary
oxidant passages; the one or more sensors further including: an
oxidant pressure sensor for sensing an oxidant pressure at one or
more of upstream of the staging valve, downstream of the staging
valve in the primary oxidant passage, and downstream of the staging
valve in the secondary oxidant passage; and a staging valve
position sensor for sensing a staging valve position as indicative
of the relative proportion of oxidant being directed to the primary
and secondary oxidant passages; wherein the data processor is
further programmed to determine the presence or absence of one or
more of a partial obstruction of one of the primary oxidant passage
and the secondary oxidant passage and a sub-optimal staging valve
position, based on the staging valve position and the oxidant
pressure at one or more of upstream of the staging valve,
downstream of the staging valve in the primary oxidant passage, and
downstream of the staging valve in the secondary oxidant
passage.
[0017] Aspect 7: The burner with monitoring of any of Aspects 5 to
6, further comprising: two pressure sensors, one positioned on
either side of a flow restriction device in at least one of the
fuel passage, the primary oxidant passage, and the secondary
oxidant passage, for sensing a pressure upstream of the flow
restriction device, a pressure downstream of the flow restriction
device, and a differential pressure across the flow restriction
device as indicative of flow rate; wherein the data processor is
further programmed to determine the presence or absence of an
abnormal burner condition based on the differential pressure and
one of the pressures upstream and downstream of the flow
restriction device.
[0018] Aspect 8: The burner with monitoring of any of Aspects 1 to
7, further comprising: a burner block having a hot face adjacent to
the furnace; and a burner block temperature sensor for sensing a
burner block temperature near the hot face; wherein the data
processor is further programmed to receive data from the burner
block temperature sensor and to determine the presence or absence
of one or more of burner block overheating and flame asymmetry
based on the burner block temperature.
[0019] Aspect 9: The burner with monitoring of any of Aspects 1 to
8, further comprising: a position sensor for sensing a burner
installation angle, the position sensor being configured to sense
one or more of a burner pitch and a burner roll; wherein the data
processor is further programmed to determine whether the burner is
installed at a desired orientation with respect to at least one
feature of the furnace based on the burner installation angle.
[0020] Aspect 10: The burner with monitoring of any of Aspects 1 to
9, further comprising: a unique identifier on a removable component
of the burner; wherein the data processor is further programmed to
use the unique identifier to tag data for analysis purposes.
[0021] Aspect 11: The burner with monitoring of any of Aspects 1 to
10, further comprising: a data collector programmed to provide
power to individual sensors only when data is to be collected,
based on one or both of a combination of sensed data and a periodic
schedule, and taking into account the specific requirements of each
of the individual sensors; a transmitter for wirelessly
transmitting sensor data from the data collector to the data
processor; and a local power generation system for powering the
data collector, the sensors, and the transmitter.
[0022] Aspect 12: The burner with monitoring of any of Aspects 1 to
11, wherein the oxidant passage is annular and surrounds the fuel
passage.
[0023] Aspect 13: A method of determining an operating condition of
an oxy-fuel burner including a fuel passage terminating in a fuel
nozzle, a primary oxidant passage terminating in an oxidant nozzle,
and a burner block having a face adjacent to the furnace, the
method comprising: sensing burner parameters from one or more
sensors selected from the group consisting of temperature sensors,
pressure sensors, density sensors, flow sensors, position sensors,
angle sensors, contact sensors, accelerometers, optical sensors,
and combinations thereof; comparing the sensed parameters with
expected values for each said burner parameter to determine the
presence or absence of a deviation in the burner parameter; and
determining the presence of an abnormal burner condition based on
the presence of a deviation in one or more burner parameters.
[0024] Aspect 14: The method of Aspect 13, further comprising:
sensing at least one of an oxidant nozzle temperature and a fuel
nozzle temperature; comparing the at least one nozzle temperature
to a threshold temperature; and determining a potential partial
obstruction of one of the oxidant nozzle and fuel nozzle based on
an increase or decrease in the at least one nozzle temperature.
[0025] Aspect 15: The method of Aspect 14, further comprising:
sensing an oxidant pressure; and determining a potential partial
obstruction of the oxidant nozzle based on the oxidant pressure and
the at least one nozzle temperature.
[0026] Aspect 16: The method of Aspect 13 or 14, the burner further
including a secondary oxidant passage spaced apart at a fixed
distance from the primary oxidant passage and a staging valve for
proportioning oxidant between the primary and secondary oxidant
passages, the method further comprising: sensing a staging valve
position indicating the proportion of oxidant being directed to the
primary and secondary oxidant passages; determining a potential
partial obstruction of the primary oxidant passage based on the
staging valve position and the at least one nozzle temperature.
[0027] Aspect 17: The method of Aspect 13 or 14, the burner further
including a secondary oxidant passage spaced apart at a fixed
distance from the primary oxidant passage and a staging valve for
proportioning oxidant between the primary and secondary oxidant
passages, the method further comprising: sensing an oxidant
pressure from a location selected from upstream of the staging
valve, downstream of the staging valve in the primary oxidant
passage, and downstream of the staging valve in the secondary
oxidant passage; sensing a staging valve position indicating the
proportion of oxidant being directed to the primary and secondary
oxidant passages; determining one or more of a potential partial
obstruction of one of the primary oxidant passage and the secondary
oxidant passage and a sub-optimal staging valve position based on
the staging valve position and the oxidant pressure at one or more
of upstream of the staging valve, downstream of the staging valve
in the primary oxidant passage, and downstream of the staging valve
in the secondary oxidant passage.
[0028] Aspect 18: The method of any of Aspects 13 to 17, further
comprising: sensing pressures at two locations, one on either side
of a flow restriction device in at least one of the fuel passage,
the primary oxidant passage, and the secondary oxidant passage;
determining a flow rate from the pressures at the two locations;
and determining the presence or absence of an abnormal burner
condition based on the flow rate and the pressure of at least one
of the two locations.
[0029] Aspect 19: The method of any of Aspects 13 to 18, further
comprising: sensing a burner installation angle, including at least
one of a burner pitch and a burner roll; and determining whether
the burner is installed at a desired orientation with respect to at
least one feature of the furnace based on the burner installation
angle.
[0030] Aspect 19a: The method of any of Aspects 13 to 19, wherein
the oxidant passage is annular and surrounds the fuel passage.
[0031] Aspect 20: An oxy-fuel burner with monitoring, comprising: a
fuel passage having a fuel nozzle at a tip end and a fuel inlet
distal from the tip end; a primary oxidant passage surrounding the
fuel passage; a temperature sensor positioned in the fuel nozzle at
the tip end of the fuel passage for sensing a fuel temperature; a
fuel pressure sensor positioned near the fuel inlet for sensing a
fuel pressure; and an instrument enclosure for receiving data from
the sensors.
[0032] Aspect 21: The burner with monitoring of Aspect 19 or 20
further comprising: a secondary oxidant passage spaced apart at a
fixed distance from the primary oxidant passage; a staging valve
for proportioning oxidant between the primary and secondary oxidant
passages; an oxidant pressure sensor positioned upstream and/or
downstream of the staging valve for sensing an oxidant inlet
pressure; and a staging valve position sensor for sensing a staging
valve position as indicative of the relative proportion of oxidant
being directed to the primary and secondary oxidant passages.
[0033] Aspect 22: The burner with monitoring of Aspect 20 or 21,
further comprising: a data processor for receiving data from the
sensors, wherein the data processor is programmed to determine
based on data received from one or more sensors the presence or
absence of an abnormal burner condition or sensor malfunction.
[0034] Aspect 23: The burner with monitoring of any of Aspects 20
to 22, further comprising: a position sensor for sensing an
installation angle of the burner and optionally parts that the
burner is mounted to; wherein the installation angle of the burner
is usable to further indicate whether the burner is installed at a
desired orientation and/or slope with respect to the furnace.
[0035] Aspect 24: The burner with monitoring of any of Aspects 20
to 24, further comprising: a unique identifier on the primary
oxidant passage; wherein the primary oxidant passage identifier is
usable to tag data for analysis purposes.
[0036] Aspect 25:The burner with monitoring of any one of Aspects
20 to 24, the instrument enclosure comprising: a data collector
programmed to provide power to individual sensors only when data is
to be collected, based on one or both of a combination of sensed
data and a periodic schedule, and taking into account the specific
requirements of each of the individual sensors; and a transmitter
for wirelessly transmitting sensor data from the data collector to
a data center.
[0037] Aspect 26: The burner with monitoring of Aspect 25, the
instrument enclosure further comprising: a local power generation
system for powering the data collector, the sensors, and the
transmitter.
[0038] Aspect 27: An oxy-fuel burner with monitoring, comprising: a
primary first reactant passage terminating in a first reactant
nozzle; a primary second reactant passage terminating in a second
reactant nozzle; one or more sensors including a temperature sensor
for sensing a nozzle temperature of at least one of the reactant
nozzles; and a data processor programmed to receive data from the
sensors and to determine based on at least a portion of the
received data the presence or absence of an abnormal burner
condition including a potential partial obstruction of at least one
of the primary first reactant passage and the primary second
reactant passage based on an increase or decrease in at least one
of the reactant nozzle temperatures; wherein one of the first and
second reactants is a fuel and the other of the first and second
reactants is an oxidant.
[0039] Aspect 28: The burner with monitoring of Aspect 27, wherein
the one or more sensor is a nozzle temperature sensor for sensing
the first reactant nozzle temperature, and wherein the data
processor is programmed to identify a potential partial obstruction
of the primary first reactant passage based on an increase or
decrease in the first reactant nozzle temperature.
[0040] Aspect 29: The burner with monitoring of Aspect 27 or 28,
wherein the data processor is programmed to base its determination
at least in part upon changes in at least a portion of the received
data with time.
[0041] Aspect 30: The burner with monitoring of any of Aspects 27
to 29, the one or more sensors further including a first reactant
pressure sensor positioned in the primary first reactant passage
for sensing a primary oxidant pressure; wherein the data processor
is programmed to identify a potential partial obstruction of the
primary first reactant passage based on a change to the primary
first reactant pressure and the at least one nozzle
temperature.
[0042] Aspect 31: The burner with monitoring of any of Aspects 27
to 29, further comprising: a secondary first reactant passage
spaced apart at a fixed distance from the primary first reactant
passage; and a staging valve for proportioning the first reactant
between the primary and secondary first reactant passages; the one
or more sensors further including a staging valve position sensor
for sensing a staging valve position as indicative of the relative
proportion of the first reactant being directed to the primary and
secondary first reactant passages; wherein the data processor is
further programmed to determine the presence or absence of a
partial obstruction of the primary first reactant passage based on
the staging valve position and the at least one nozzle
temperature.
[0043] Aspect 32: The burner with monitoring of any of Aspects 27
to 29, further comprising: a secondary first reactant passage
spaced apart at a fixed distance from the primary first reactant
passage; and a staging valve for proportioning the first reactant
between the primary and secondary first reactant passages; the one
or more sensors further including: a first reactant pressure sensor
for sensing a first reactant pressure at one or more of upstream of
the staging valve, downstream of the staging valve in the primary
first reactant passage, and downstream of the staging valve in the
secondary first reactant passage; and a staging valve position
sensor for sensing a staging valve position as indicative of the
relative proportion of the first reactant being directed to the
primary and secondary first passages; wherein the data processor is
further programmed to determine the presence or absence of one or
more of a partial obstruction of one of the primary first reactant
passage and the secondary first reactant passage and a sub-optimal
staging valve position based on the staging valve position and the
first reactant pressure at one or more of upstream of the staging
valve, downstream of the staging valve in the primary first
reactant passage, and downstream of the staging valve in the
secondary first reactant passage.
[0044] Aspect 33: The burner with monitoring of any of Aspects 31
and 32, further comprising: two pressure sensors, one positioned on
either side of a flow restriction device in at least one of the
primary first reactant passage, the primary second reactant
passage, and the secondary first reactant passage, for sensing a
pressure upstream of the flow restriction device, a pressure
downstream of the flow restriction device, and a differential
pressure across the flow restriction device as indicative of flow
rate; wherein the data processor is further programmed to determine
the presence or absence of an abnormal burner condition based on
the differential pressure and one of the pressure upstream and
downstream of the flow restriction device.
[0045] Aspect 34: The burner with monitoring of any of Aspects 27
to 33, further comprising: a burner block having a hot face
adjacent to the furnace; and a burner block temperature sensor for
sensing a burner block temperature near the hot face; wherein the
data processor is further programmed to determine the presence or
absence of one or more of burner block overheating and flame
asymmetry based on the burner block temperature.
[0046] Aspect 35: The burner with monitoring of any of Aspects 27
to 34, further comprising: a position sensor for sensing a burner
installation angle, the position sensor being configured to sense
one or more of a burner pitch and a burner roll; wherein the data
processor is further programmed to determine whether the burner is
installed at a desired orientation with respect to at least one
feature of the furnace based on the burner installation angle.
[0047] Aspect 36: The burner with monitoring of any of Aspects 27
to 35, further comprising: a data collector programmed to provide
power to individual sensors only when data is to be collected,
based on one or both of a combination of sensed data and a periodic
schedule, and taking into account the specific requirements of each
of the individual sensors; a transmitter for wirelessly
transmitting sensor data from the data collector to the data
processor; and a local power generation system for powering the
data collector, the sensors, and the transmitter.
[0048] Aspect 37: The burner with monitoring of any of Aspects 27
to 36, wherein the first reactant passage is annular and surrounds
the second reactant passage.
[0049] Aspect 38: The burner with monitoring of any of Aspects 27
to 37, wherein the first reactant is a fuel and the second reactant
is an oxidant.
[0050] Aspect 39: The burner with monitoring of any of Aspects 27
to 37, wherein the first reactant is an oxidant and the second
reactant is a fuel.
[0051] Aspect 40: A method of determining an operating condition of
an oxy-fuel burner including a first reactant passage terminating
in a first reactant nozzle, a primary second reactant passage
terminating in a second reactant nozzle, and a burner block having
a face adjacent to the furnace, the method comprising: sensing
burner parameters from one or more sensors selected from the group
consisting of temperature sensors, pressure sensors, flow sensors,
position sensors, angle sensors, contact sensors, accelerometers,
optical sensors, and combinations thereof; comparing the sensed
parameters with expected values for each said burner parameter to
determine the presence or absence of a deviation in the burner
parameter; and determining the presence of an abnormal burner
condition based on the presence of a deviation in one or more
burner parameters.
[0052] Aspect 41: The method of Aspect 40, further comprising:
sensing at least one of a first reactant nozzle temperature and a
second reactant nozzle temperature; comparing the at least nozzle
temperature to a threshold temperature; and determining a potential
partial obstruction of one of the first and second reactant nozzles
based on an increase or decrease in the at least one nozzle
temperature.
[0053] Aspect 42: The method of Aspect 40 or 41, further
comprising: sensing a first reactant pressure; and determining a
potential partial obstruction of the first reactant nozzle based on
the first reactant pressure and the at least one nozzle
temperature.
[0054] Aspect 43: The method of Aspect 40 or 41, the burner further
including a secondary first reactant passage spaced apart at a
fixed distance from the primary first reactant passage and a
staging valve for proportioning the first reactant between the
primary and secondary first reactant passages, the method further
comprising: sensing a staging valve position indicating the
proportion of the first reactant being directed to the primary and
secondary first reactant passages; determining a potential partial
obstruction of the primary first reactant passage based on the
staging valve position and the at least one nozzle temperature.
[0055] Aspect 44: The method of Aspect 40 or 41, the burner further
including a secondary first reactant passage spaced apart at a
fixed distance from the primary first reactant passage and a
staging valve for proportioning the first reactant between the
primary and secondary first reactant passages, the method further
comprising: sensing a first reactant pressure from a location
selected from upstream of the staging valve, downstream of the
staging valve in the primary first reactant passage, and downstream
of the staging valve in the secondary first reactant passage;
sensing a staging valve position indicating the proportion of the
first reactant being directed to the primary and secondary first
reactant passages; determining one or more of a potential partial
obstruction of one of the primary first reactant passage and the
secondary first reactant passage and a sub-optimal staging valve
position based on the staging valve position and the first reactant
pressure at one or more of upstream of the staging valve,
downstream of the staging valve in the primary first reactant
passage, and downstream of the staging valve in the secondary first
reactant passage.
[0056] Aspect 45: The method of any of Aspects 40 to 44, further
comprising: sensing pressures from two locations, one on either
side of a flow restriction device in at least one of the second
reactant passage, the primary first reactant passage, and the
secondary first reactant passage; determining a flow rate from the
pressures at the two locations; and determining the presence or
absence of an abnormal burner condition based on the flow rate and
the pressure of at least one of the two locations.
[0057] Aspect 46: The method of any of Aspects 40 to 45, further
comprising: sensing a burner installation angle, including at least
one of a burner pitch and a burner roll; and determining whether
the burner is installed at a desired orientation with respect to at
least one feature of the furnace based on the burner installation
angle.
[0058] Aspect 47: The method of any of Aspects 40 to 46, wherein
the first reactant passage is annular and surrounds the second
reactant passage.
[0059] Aspect 48: The method of any of Aspects 40 to 47, wherein
the first reactant is a fuel and the second reactant is an
oxidant.
[0060] Aspect 49: The method of any of Aspects 40 to 47, wherein
the first reactant is an oxidant and the second reactant is a
fuel.
[0061] Other aspects of the invention are described below.
BRIEF DESCRIPTION OF THE DRAWINGS
[0062] FIG. 1A is rear perspective view of an oxy-oil burner with
monitoring for insertion into a burner block.
[0063] FIG. 1B is a rear perspective view of an oxy-oil burner with
monitoring as in FIG. 1A inserted in a burner block.
[0064] FIG. 2 is a front perspective view of an oxy-oil burner
similar to the burner in FIG. 1A inserted in a burner block, but
without monitoring capabilities.
[0065] FIG. 3 is a rear perspective view of an oil lance for use in
an oxy-oil burner with monitoring as in FIG. 1A.
[0066] FIG. 4 as a partial side view of an oil lance showing o-ring
seals for maintaining and oil seal with the oil lance around a
sensor access port.
[0067] FIG. 5 is a cross-sectional view of an oxy-oil burner with
monitoring inserted in a burner block.
[0068] FIG. 6 is a graph showing exemplary pressure data comparing
the difference between the oil inlet pressure and the atomizing gas
inlet pressure for a fuel oil at different temperatures.
[0069] FIG. 7 is a graph showing exemplary pressure data comparing
the difference between the oil inlet pressure and the atomizing gas
inlet pressure for two fuel oil compositions and showing
differences for one of those fuel oil compositions when the nozzle
tip is partially clogged, and when a temperature excursion
occurred.
[0070] FIG. 8 is a schematic showing components of a communication
system for collecting, transmitting, and analyzing data collected
from various sensors on a burner, and for providing local power
generation to a data center.
[0071] FIG. 9 is a rear perspective view of an oxy-gas burner with
monitoring for insertion into a burner block.
[0072] FIG. 10 is a partially cut away rear perspective view of an
oxy-gas burner with monitoring as in FIG. 9.
[0073] FIG. 11 is a cross-sectional view of an oxy-gas burner with
monitoring inserted in a burner block.
[0074] FIG. 12 is a rear perspective view of an oxy-gas burner with
monitoring as in FIG. 9 inserted in a burner block.
[0075] FIG. 13 is a graph illustrating exemplary effects of a
blockage in front of a burner on oxygen pressure, natural gas
pressure, and burner tip temperature.
[0076] FIG. 14 is a graph illustrating exemplary effects of a
blockage at a burner outlet on oxygen pressure, natural gas
pressure, and burner tip temperature.
[0077] FIG. 15 is a graph comparing oxygen pressure fluctuations in
the same burner with and without an obstruction placed at the
burner outlet.
[0078] FIG. 16 is a graph illustrating the variations in oxygen
pressure as a function of firing rate and staging ratio.
[0079] FIG. 17A shows the pitch (angular deviation about an axis
perpendicular to a longitudinal burner axis) and roll (angular
deviation about an axis coincident with the longitudinal burner
axis), and FIG. 17B shows the effect of pitch and roll on flame
impingement at the burner face, where pitch and roll are normalized
to zero for operation with no flame impingement.
[0080] FIGS. 18A and 18B are a top view and a front view,
respectively, of a burner mounted in a burner block, showing
thermocouples mounted in a grid in the burner block at front,
middle, and rear locations axially, as well as at left, middle, and
right locations laterally. FIG. 18C shows measured block
temperature at the lateral middle location for a misaligned burner
that was fired first with 100% staging (relatively flat temperature
curves) and then 0% staging (upward sloping temperature
curves).
[0081] FIG. 19 is a graph illustrating fuel oil lance tip
temperature, oil pressure, and atomization pressure for an oxy-oil
burner as in FIG. 1A, showing an lance temperature increasing
steadily over time prior to cleaning of the oil nozzle, but oil
pressure and atomization pressure not showing the same clear
trend.
[0082] FIG. 20 is a graph illustrating fuel oil lance tip
temperature for an oxy-oil burner as in FIG. 1A at several
different oxygen staging ratios.
DETAILED DESCRIPTION
[0083] Described herein is a burner system configured to be able to
detect an abnormal burner condition, which may include, but is not
limited to, partial obstruction of a flow passage, overheating of a
portion of the burner, and/or improper installation orientation,
and also to distinguish an abnormal burner condition from sensor
failure.
[0084] FIGS. 1A, 1B, 2, and 5 depict an embodiment of a staged
oxy-oil burner 10 with integrated sensors, power supply, and
communications equipment. FIGS. 9, 10, and 12 depict an embodiment
of a staged oxy-gas burner 310 with integrated sensors. Although
particular embodiments of burners, either oxy-oil or oxy-gas, are
described herein as an exemplary embodiments of a burner with
monitoring, the same or similar communications equipment and
methods, along with similar or analogous integrated sensors,
customized to the configuration, design, and operational mode of
the particular burner, can be used on burners that combust gaseous
fuel, liquid fuel, or solid fuel with an oxidant. In particular,
with the exception of parameters that relate specifically to oil
combustion, such as the oil and atomizing gas inlet pressures, all
of the parameters and sensors described herein similarly apply to a
burner for combusting any fuel, including gaseous fuel, solid fuel
(e.g., petcoke) in a carrier gas, or liquid fuel.
[0085] Additionally, in a staged oxy-fuel burner, one or both of
fuel and oxidant (e.g., oxygen) is staged such that a primary
stream participates in initial combustion while a secondary stream
participates in delayed combustion away from the burner. For
example, for oxidant staging, the oxidant is proportioned between a
primary oxidant passage and a secondary oxidant passage, with the
secondary oxidant being supplied to at least one secondary oxidant
nozzle spaced apart from the primary oxidant nozzle(s) and fuel
nozzle(s). Such staging may be accomplished by a staging valve
upstream of the primary and secondary oxidant passages that
proportions one incoming oxidant stream between the two passages.
Alternatively, the flow to each of the primary and secondary
oxidant passages may be independently controlled, manually or
automatically, by a separate control valve or by fixed flow
restrictors. In other burners, fuel may be staged similarly, using
either a staging valve or separate flow controls for primary and
secondary streams. Further, in some burners, both fuel and oxidant
may be staged.
[0086] The power supply is preferably a battery or local power
generation for ease of installation and to avoid possible safety
issues with wired power. The sensors may include, in any
combination, temperature sensors, pressure sensors, density
sensors, flow sensors, position sensors, angle sensors, contact
sensors, accelerometers, and optical sensors.
[0087] Examples of burners such as the burner 10 and the burner
310, but without sensors, are described in U.S. Pat. Nos.
5,575,637, 5,611,682, 7,390,189, 8,172,566, and 8,512,033, which
are incorporated herein by reference in their entirety.
[0088] The burner 10 has a discharge end 51 and an inlet end 19.
For convenience of description, the discharge end 51 is sometimes
referred to herein as the front or forward direction of the burner
10, while the inlet end 19 is sometimes referred to as the rear or
rearward direction of the burner 10. When the burner 10 is mounted
in a furnace, the discharge end 51 faces the interior of the
furnace.
[0089] The burner 10 includes a burner block 12, a burner body 14
positioned rearward from burner block 12 with respect to the
furnace, and an instrument enclosure 16 positioned rearward with
respect to the burner body 14. The burner body 14 includes a
mounting plate 53 that is secured to the burner block 12. The
burner block 12 has a front face 18 that, when mounted, faces into
the furnace.
[0090] The burner block 12 includes a primary oxidant passage 30.
In the depicted embodiment, the primary oxidant passage 30 has an
elongated cross-sectional shape with a major axis (defining a
width) longer than a minor axis (defining a height). In particular,
the depicted primary oxidant passage 30 has the shape of a
rectangle with semi-circular ends, and a width-to-height ratio from
about 5 to about 30. However, in other embodiments, the primary
oxidant passage 30 may have a circular, oval, ovalized rectangular,
rectangular, or other shape.
[0091] An oil lance 20 is positioned within the primary oxidant
passage 30 and has an oil nozzle 22 at its discharge end. In the
depicted embodiment, the oil nozzle is an atomizing nozzle 22. The
atomizing nozzle 22 is substantially surrounded by the primary
oxidant passage 30 so that atomized fuel oil discharged from the
nozzle 22 will mix intimately with the primary oxidant stream upon
discharge. Preferably, the oil lance 20 and the nozzle 22 are
separately manufactured parts that are joined together, for example
by welding, to form a unitary lance with nozzle. In the depicted
embodiment, the oil lance 20 substantially centrally positioned
within the primary oxidant passage 30, although it is understood
that the oil lance 20 may be located in a non-central location
provided the nozzle 22 is adapted to distribute the atomized oil to
be adequately mixed with the primary oxidant stream for combustion.
Alternatively, for an oxy-gas burner, a gaseous fuel passage can be
positioned within the primary oxidant passage 30 in place of the
oil lance 20.
[0092] The burner block 12 further includes a secondary oxidant
passage 40 spaced apart by a fixed distance from the primary
oxidant passage 30. In the depicted embodiment, the secondary
oxidant passage 40 has an elongated cross-sectional shape with a
major axis (defining a width) longer than a minor axis (defining a
height), similar to the primary oxidant passage 30. In particular,
the depicted secondary oxidant passage 40 has the shape of a
rectangle with semi-circular ends, and a width-to-height ratio from
about 5 to about 30, which may be the same as or different from the
width-to-height ratio of the primary oxidant passage 30. The major
axis of the secondary oxidant passage 40 is substantially parallel
to the major axis of the primary oxidant passage 30. However, in
other embodiments, the second oxidant passage 40 may have a
circular, oval, ovalized rectangular, rectangular, or other shape,
and preferably but not necessarily approximately the same shape as
the primary oxidant passage 30.
[0093] The primary oxidant passage 30 is fed oxidant from a primary
oxidant conduit 32 positioned in the burner body 14 and extending
into a rear portion of the burner block 12. Oxidant is fed through
a pair of oxidant inlets 38 into an oxidant plenum 36 that in turn
feeds the primary oxidant conduit 32. A diffuser 34 may be
positioned between the oxidant inlets 38 and the oxidant plenum 36
to aid in straightening out the primary oxidant flow prior to
entering the primary oxidant conduit 32.
[0094] The secondary oxidant passage 40 is fed oxidant from a
secondary oxidant conduit 42 positioned in the burner body 14 and
extending into a rear portion of the burner block 12. A staging
valve 48 in the burner body 14 redirects a portion of the oxidant
supplied by the oxidant inlets 38 into the secondary oxidant
conduit 42. The term "staging ratio" is used to describe the
proportion of oxidant that is redirected to the secondary oxidant
conduit 42, and thus away from the primary oxidant conduit 32. For
example, at a staging ratio of 30%, 70% of the oxidant is directed
to the primary oxidant conduit 32 (and thus to the primary oxidant
passage 30) as a primary oxidant stream and 30% of the oxidant is
directed to the secondary oxidant conduit 42 (and thus to the
secondary oxidant passage 40) as a secondary oxidant stream.
[0095] The oxidant gas fed to the oxidant inlets 38 may be any
oxidant gas suitable for combustion, including air, oxygen-enriched
air, and industrial grade oxygen. The oxidant preferably has a
molecular oxygen (O2) content of at least about 23 mol %, at least
about 30 mol %, at least about 70 mol %, or at least about 98 mol
%.
[0096] The oil lance 20 extends rearward through the burner body 14
and through the instrument enclosure 16. Fuel oil is supplied to
the oil lance 20 through an oil inlet 26. Due to the viscosity of
fuel oil, it is typically necessary to also supply an atomizing gas
to the oil lance 20 through an atomizing gas inlet 28. The
atomizing gas may be any gas capable of atomizing the fuel oil as
it exits the nozzle 22, including air, oxygen-enriched air, or
industrial grade oxygen.
[0097] Various temperature sensors may be used for monitoring the
temperature of burner components and for help in determining fuel
inlet conditions. In the depicted embodiment of FIGS. 1A, 1B, 2,
and 5, a temperature sensor 102 such as a thermocouple is embedded
in the atomizing nozzle 22 in the oil lance 20 for measuring the
temperature at the discharge end of the oil lance 20. The
temperature sensor 102 may be a thermocouple or any other suitable
sensor. The sensor 102 is fitted into a blind hole (not shown) in a
rear side of the nozzle 22. Because the sensor 102 must be
removable for maintenance and replacement, it is not welded in
place. Leads (not shown) connected to the temperature sensor 102
are routed back along the oil lance 20 to the instrument enclosure
16. To protect the leads 104 from abrasion, overheating, and other
harsh conditions of the furnace environment, it is desirable to
encase the leads. However, it is difficult from a manufacturing
perspective to form a small diameter hole for a substantial portion
of the length of the oil lance 20. Therefore, the leads are
preferably recessed in a channel 106 along the length of the lance,
and a sheath (not shown) is positioned over the channel 106 to
protect the leads. In one embodiment, the sheath mates with an
outer wall of the lance 20 to seal the leads and temperature sensor
102 from the furnace environment, to provide mechanical protection
to the leads and temperature sensor 102, and to limit the flow
disturbances of the primary oxidant stream flowing in the primary
oxidant passage 30 and around the oil lance 20.
[0098] Temperature sensors may be placed on other components of the
burner 10 to monitor operational parameters such as burner
integrity, flame stability, flame position. For example, one or
more temperature sensors 110 may be mounted in the burner block 12
near the front face 18 or near the flow passages. The temperature
sensors 110 are preferably set back slightly from the front face 18
to protect them from the furnace environment. The temperature
sensors 110 may be centered with respect to the primary oxidant
passage 30, or offset from the minor axis centerline. and may be
used to determine whether the flame is impinging on the burner
block 12 or whether the flame is centered about the oil lance 20 or
the primary oxidant passage 30. Temperature sensors may even be
positioned in other locations of the furnace proximate to the
burner for monitoring combustion conditions. Optical sensors may
also, or alternatively, be used to monitor the light intensity from
the block, with increased emissions from the block indicating
potential flame impingement.
[0099] An oil feed temperature sensor 112 is positioned in the oil
stream near the oil inlet 26 to monitor the temperature of the oil
being supplied to the burner 10. It is important to ensure that the
viscosity of the oil stream will enable proper oil atomization, and
the viscosity is a function of temperature as well as oil
composition. Therefore, for any particular oil composition, an
optimum temperature range can be determined for atomization.
[0100] The oil feed temperature sensor 112 must be able to measure
the oil inlet temperature, but is preferably also positioned so as
to permit lance cleaning without removing the temperature sensor
112. In the depicted embodiment of a rear portion of the oil lance
20 in FIG. 4, a sealing mechanism 61 is provided at the rear
portion of the lance 20. The sealing mechanism 61 includes a body
23 through which the bore 21 extends in a longitudinal direction,
and a sleeve 64 surrounding the body 23. The sealing mechanism 61
enables the temperature sensor 112 to be near the flowing oil
stream in the lance 20 but also out of the way of the bore 21 of
the lance 20, so that the bore 21 can be cleaned and so that the
body 23 can be removed from the sleeve 64 without removing the
temperature sensor 112. The body 23 includes a sensor well 68
surrounded to the front and rear by two pairs of o-rings 70 seated
in o-ring grooves 72, which seal against an inner surface 74 of the
sleeve 64. An access opening 69, or multiple such openings, enables
oil flowing through the bore 21 to enter the sensor well 68.
[0101] A sensor port 67 is located in the sleeve 64, and the
temperature sensor 112 is secured (e.g., by threads or other
mechanism) into the sensor port 67 so as to have its sensing tip
flush with or slightly recessed from the inner surface 74 of the
sleeve 64. Experiments have shown that a temperature sensor 112
mounted as shown and described is appropriately sensitive in
responding to changes in oil inlet temperature. Consequently, the
temperature sensor 112 is able to measure the oil temperature in
the bore 21, or at least a temperature that has experimentally
shown to be accurately representative of the oil temperature, while
still permitting the body 23 to be removed from the sleeve 64 for
cleaning without having to disturb the temperature sensor 112.
[0102] Because the sensor well 68 extends around the entire
circumference of the body 23, the body 23 may include multiple
sensor ports 67 to enable mounting of multiple sensors. Also,
multiple access openings 69 may be present to provide better
uniformity of the oil in the sensor well 68. This arrangement
allows the oil stream to contact the temperature sensor 112 while
maintaining a seal with the sleeve 64 to prevent any oil leakage.
Specifically, by mounting the temperature sensor 112 nearly flush
with the bore, the temperature sensor 112 is in contact with oil
that is indicative of current oil temperatures. Also, by being
flush or nearly flush, the temperature sensor 112 will not block
physical components that are inserted into the bore 21 of the oil
lance 20 for cleaning and to allow the body 23 to be removed from
the oil lance 20 for cleaning. In one embodiment, the temperature
sensor 112 may be fitted with a male NPT fitting to mate with a
female NPT thread in the sensor port 67.
[0103] In the depicted embodiment, pressure sensors are also
installed in the burner 10. A pressure sensor 114 is positioned in
the oil stream near the oil inlet 26. The pressure sensor 114 may
be mounted in the same sealing mechanism 61 as the temperature
sensor 112, with the pressure sensor 114 being located in a
different sensor port (not shown). Alternatively, the pressure
sensor 114 may be mounted in a separate sealing mechanism having
essentially the same construction as the sealing mechanism 61.
[0104] In the embodiment of FIG. 5, a pressure sensor 116 is
mounted in the atomizing gas stream near the atomizing gas inlet
28, and a pressure sensor 128 is mounted in the oxidant stream
either near one of the oxidant inlets 38 or in the oxygen plenum 36
upstream of the staging valve 48. If desired, separate oxidant
pressure sensors may be mounted in each of the primary oxidant
conduit 32 and the secondary oxidant conduit 42 to detect the
pressure of oxidant being supplied to each of the oxidant passages
30 and 40, respectively, in the burner block 12. The pressure
sensors may be located inside or outside of the instrument
enclosure 16, and are wired by cable for both power supply and
signal transmission.
[0105] As shown, the instrument enclosure 16 includes a battery
port 81 and an antenna 62 for wireless communication of data.
[0106] Note that similar configurations to the foregoing could be
used to mount other sensors to monitor any of the feed streams.
[0107] In the depicted embodiment of FIGS. 1A to 5, the burner 10
also has a position sensor or rotation sensor 124 on the staging
valve 48 to detect the percent staging. The rotation sensor 124
could be a Hall effect type sensor, accelerometer type sensor, a
potentiometer, optical sensor, or any other sensor that can
indicate rotational position. Additional position and angle sensors
may be used to determine the position and/or angle of the burner
body 14 relative to the furnace or the burner block 12, the
position and/or angle of the lance 20 relative to the burner body
14 or the burner block 12, the insertion depth of the lance 20, and
any other angles or positions that may be relevant to the operation
of the burner 10.
[0108] For example, position sensors on the oil lance 20 can be
used to detect and verify correct insertion depth and to log the
information for tracking performance. Angle sensors on the burner
10 can be used to ensure that the burner is installed properly.
This could be for ensuring that the burner is seated properly
against the mounting plate for seating positive seal. In addition
it is sometime desirable to install the burner at a given angle
with respect to horizontal. Other sensors such as contact sensors
between the burner and mounting plate could be used to ensure
proper mounting of the burner to the mounting plate. By using one
or more such sensors (preferably at least two) the burner can do a
check on its installation to ensure that it is not ajar and is
indeed in contact with both sensors (for example, a top sensor and
a bottom sensor, or a left sensor and right sensor, or all four
positions).
[0109] Additional connection ports may be located on the oil lance
20, the burner body 14, and/or the burner block 12 to enable
additional external sensors or other signals to be connected to the
data collector for transmission to a data indicator.
[0110] In one embodiment of the system of FIGS. 1A to 5 (or
similarly the system of FIGS. 9 to 12), one or more burner
components have a unique identifier. Specifically for a oil burner
10, the body 14 and each oil lance 20 may each have a unique
identifier. This is useful since oil lances can be separated from
the burner body and may be switched to different burner bodies. By
incorporating a unique identifier on the burner body and lance, the
communications equipment in the instrument box, which travels with
the lance, can identify which burner body it is connected to for
historical data archiving, trend analysis, and other reasons. This
identifier could be RFID, a type of wireless transmitter, bar code,
a one-wire silicon serial number, a unique resistor, a coded
identifier, or any other identifying means.
[0111] Measuring the oil pressure can provide information about the
flow resistance of the oil lance (e.g., decreased flow area due to
coking or some other blockage will cause a pressure rise), the
flowrate of the oil, and the viscosity of the oil (which is a
function of temperature and composition). The oil pressure
information is likely to be more useful when combined with other
information (e.g., the oil temperature, the oil flowrate, the
burner tip temperature, and data trending) in detecting maintenance
needs of the oil lance.
[0112] Measuring the atomizing oxidant pressure also provides
information about the oil flowrate and resistance and is therefore
related to the oil pressure, but it is typically not the same and
provides another element of information. Both of these instruments
are located within the instrument box on the oil lance.
[0113] The oxygen pressure measurement provides information about
the oxygen flowrate, flow resistance (i.e. blockage that may
occur), and staging valve position.
[0114] The instrument enclosure 16, which is shown in partial
cutaway in FIGS. 1A and 1B, is sealed and insulated to protect
instrumentation contained therein from the dust and heat of a
furnace environment. The instrument enclosure is positioned toward
the rear 19 of the burner 10 to reduce the radiant heat energy
received from the furnace. The instrument enclosure 16 includes at
least a data collector 60, a power supply, and a transmitter 62 for
sending data from the data collector to a data receiver 200 (which
may collect and display data from multiple burners) located either
locally or remotely. In one embodiment, the transmitter 62 is
incorporated into the data collector 60. A data processor processes
the data from all of the sensors and may be incorporated into the
data collector 60 (e.g., data processor 66), located in the
instrument enclosure 316 separately from the data collector 60
(e.g., data processor 166), or located at a remote location
integral with or separate from the data receiver 200 (e.g., data
processor 266).
[0115] In the embodiment depicted in FIGS. 9, 10, 11, and 12, the
burner 310 has a discharge end 351 and an inlet end 319. For
convenience of description, the discharge end 351 is sometimes
referred to herein as the front or forward direction of the burner
310, while the inlet end 319 is sometimes referred to as the rear
or rearward direction of the burner 310. When the burner 310 is
mounted in a furnace, the discharge end 351 faces the interior of
the furnace.
[0116] The burner 310 includes a burner block 312, a burner body
314 positioned rearward from burner block 312 with respect to the
furnace, and an instrument enclosure 316 positioned rearward with
respect to the burner body 314. The burner body 314 includes a
mounting plate 353 that is secured to the burner block 312. The
burner block 312 has a front face 318 that, when mounted, faces
into the furnace.
[0117] The burner 310 includes a primary oxidant passage 330. In
the depicted embodiment, the primary oxidant passage 330 has an
elongated cross-sectional shape with a major axis (defining a
width) longer than a minor axis (defining a height). In particular,
the depicted primary oxidant passage 330 has the shape of a
rectangle with semi-circular ends, and a width-to-height ratio from
about 5 to about 30. However, in other embodiments, the primary
oxidant passage 330 may have a circular, oval, ovalized
rectangular, rectangular, or other shape. The primary oxidant
passage has a primary oxidant nozzle 333 at its discharge end.
[0118] A fuel passage 320 is positioned within the primary oxidant
passage 330 and has a fuel nozzle 322 at its discharge end. The
fuel nozzle 322 is substantially surrounded by the primary oxidant
nozzle 333 so that fuel discharged from the fuel nozzle 322 will
mix intimately with the primary oxidant stream from the oxidant
nozzle 333 upon discharge. In the depicted embodiment, the fuel
passage 320 has an elongated cross-sectional shape with a major
axis (defining a width) longer than a minor axis (defining a
height). In particular, the depicted fuel passage 320 has the shape
of a rectangle with semi-circular ends, and a width-to-height ratio
from about 5 to about 30.However, in other embodiments, the fuel
passage 320 may have a circular, oval, ovalized rectangular,
rectangular, or other shape. In the depicted embodiment, the fuel
passage 320 is substantially centrally positioned within the
primary oxidant passage 330, although it is understood that the
fuel passage 320 may be located in a non-central location provided
the fuel nozzle 322 is adapted to distribute the fuel to be
adequately mixed with the primary oxidant stream for combustion.
Preferably, but not necessarily, the fuel passage 320 approximately
the same shape as the primary oxidant passage 330.
[0119] The burner 310 further includes a secondary oxidant passage
340 spaced apart by a fixed distance from the primary oxidant
passage 330. In the depicted embodiment, the secondary oxidant
passage 340 has an elongated cross-sectional shape with a major
axis (defining a width) longer than a minor axis (defining a
height), similar to the primary oxidant passage 330. In particular,
the depicted secondar oxidant passage 340 has the shape of a
rectangle with semi-circular ends, and a width-to-height ratio from
about 5 to about 30, which may be the same as or different from the
width-to-height ratio of the primary oxidant passage 330. The major
axis of the secondary oxidant passage 340 is substantially parallel
to the major axis of the primary oxidant passage 330. However, in
other embodiments, the second oxidant passage 340 may have a
circular, oval, ovalized rectangular, rectangular, or other shape,
and preferably but not necessarily approximately the same shape as
the primary oxidant passage 330.
[0120] The primary oxidant passage 330 is fed oxidant from a
primary oxidant conduit 332 positioned in the burner body 314 and
extending into a rear portion of the burner block 312. Oxidant is
fed through a pair of oxidant inlets 338 into an oxidant plenum 335
that in turn feeds the primary oxidant conduit 332. A diffuser 334
may be positioned between the oxidant inlets 338 and the oxidant
plenum 335 to aid in straightening out the primary oxidant flow
prior to entering the primary oxidant conduit 332.
[0121] The secondary oxidant passage 340 is fed oxidant from a
secondary oxidant conduit 342 positioned in the burner body 314 and
extending into a rear portion of the burner block 312. A staging
valve 348 in the burner body 314 redirects a portion of the oxidant
supplied by the oxidant inlets 338 into the secondary oxidant
conduit 342. The term "staging ratio" is used to describe the
proportion of oxidant that is redirected to the secondary oxidant
conduit 342, and thus away from the primary oxidant conduit 332.
For example, at a staging ratio of 30%, 70% of the oxidant is
directed to the primary oxidant conduit 332 (and thus to the
primary oxidant passage 330) as a primary oxidant stream and 30% of
the oxidant is directed to the secondary oxidant conduit 342 (and
thus to the secondary oxidant passage 340) as a secondary oxidant
stream.
[0122] The oxidant gas fed to the oxidant inlets 338 may be any
oxidant gas suitable for combustion, including air, oxygen-enriched
air, and industrial grade oxygen. The oxidant preferably has a
molecular oxygen (O2) content of at least about 23 mol %, at least
about 30 mol%, at least about 70 mol %, or at least about 98 mol
%.
[0123] The fuel passage 320 extends rearward through the burner
body 314 and through the instrument enclosure 316. Fuel is supplied
to the fuel passage 320 through a fuel inlet 326.
[0124] Although the embodiment described herein stages oxidant flow
and includes a primary oxidant passage 330, a secondary oxidant
passage 340, and a fuel passage 320, an analogous burner have an
analogous physical structure can be used which stages fuel flow and
includes a primary fuel passage, a secondary fuel passage, and an
oxidant passage. More generically, a burner can be described as
combusting a first reactant (which is one of a fuel and an oxidant)
and a second reactant (which is the other of a fuel and an
oxidant), the burner including a primary first reactant passage, a
secondary first reactant passage, and a second reactant
passage.
[0125] Various sensors may be used for monitoring parameters of
burner components. In the depicted embodiment of FIGS. 9, 10, 11,
and 12, various sensors are shown for monitoring and controlling
burner operation.
[0126] Temperature sensors may be placed on or in the burner 310
itself or on components of the burner 310, or in other portions of
the furnace. For example, temperature sensors on the burner 310 can
monitor operational parameters such as burner integrity, flame
stability, flame position, while temperature sensors in the furnace
can measure the temperature of the charge before, during, and after
firing of the burner to provide information about the rate of heat
transfer and distribution of heat from the burner. The sensors may
be of any type, including without limitation thermocouples and
optical (e.g., infrared) sensors.
[0127] In the depicted embodiment of FIG. 11, a temperature sensor
372 is mounted in the primary oxidant passage 330 at or near the
oxidant nozzle 333 for monitoring the temperature of the primary
oxidant passage 330 or the oxidant nozzle 333. Alternatively, or in
combination with the oxidant sensor, a temperature sensor 372 could
mounted in the fuel passage 320 at or near the fuel nozzle 322 for
monitoring the temperature of the fuel passage 320 or the fuel
nozzle 322. In other embodiments, temperature sensors may be
mounted in the burner block 312 near the front face 318 or near the
flow passages. The connection points to two temperature sensors 372
are shown in FIG. 10. When mounted in the burner face 318, the
temperature sensors 372 are preferably set back slightly from the
front face 318 to protect them from the furnace environment. The
temperature sensors 372 may be centered with respect to the primary
oxidant passage 330 or the fuel passage 320, or offset from the
minor axis centerline. and may be used to determine whether the
flame is impinging on the burner block 312 or whether the flame is
centered about the fuel passage 320 or the primary oxidant passage
330. Temperature sensors may even be positioned in other locations
of the furnace proximate to the burner for monitoring combustion
conditions. Optical sensors may also, or alternatively, be used to
monitor the light intensity from the block, with increased
emissions from the block indicating potential flame
impingement.
[0128] In the depicted embodiment of FIGS. 11 and 12, pressure
sensors are installed in the burner 310. A pressure sensor 380 is
positioned in the fuel passage 320 for measuring the fuel pressure
upstream of the fuel nozzle 322. Another pressure sensor 376 is
mounted in the oxidant stream either near one of the oxidant inlets
338, or in the oxygen plenum 335 upstream of the staging valve 348
to measure the oxidant pressure upstream of the staging valve, or
upstream of the diffuser 334 to measure oxidant inlet pressure
upstream of the diffuser 334. If desired, separate oxidant pressure
sensors may be mounted in each of the primary oxidant conduit 332
(pressure sensor 378) and/or in the secondary oxidant conduit 342
(pressure sensor 379) to measure the pressure of oxidant being
supplied to either or both of the oxidant passages 330 and 340 in
the burner block 312. The pressure sensors 378 and 379 are located
downstream of the diffuser 334, and one or both may be used in
combination with the pressure sensor 376 to determine flow rate
based on pressure drop across the diffuser 334. The pressure
sensors may be located inside or outside of the instrument
enclosure 316, and are wired by cable for both power supply and
signal transmission. The burner 310 may further include a density
sensor 388, for example as described in US Patent Pub. No.
2014/0000342, that is mounted in the fuel passage 320 (as shown)
and/or in the primary oxidant passage 330 (not shown).
[0129] As shown, the instrument enclosure 316 includes a battery
port 382 for housing a local power supply (e.g., a battery) to
provide power to the components in the instrument enclosure 116, as
well as to the various sensors. The instrument enclosure 316
further includes an antenna 62 for wireless communication of data.
The enclosure 316 also includes a position and angle sensing
apparatus 370 measuring angles as shown in FIG. 17A and discussed
in further detail below. Such position and angle sensors may be
used to determine the position and/or angle of the burner body 314
relative to the furnace or the burner block 312 and any other
angles or positions that may be relevant to the operation of the
burner 310. Additionally, the burner 310 also has a position sensor
or rotation sensor 384 on the staging valve 348 to detect the
percent staging. The rotation sensor 384 could be a Hall effect
type sensor, accelerometer type sensor, a potentiometer, optical
sensor, or any other sensor that can indicate rotational position.
The instrument enclosure 316 may also include an LED 386 or other
light source for illuminating the internals of the burner 310,
and/or for indicating burner operating status.
[0130] The oxygen pressure measurements provides information about
the oxygen flowrate, flow resistance (i.e., potential blockage that
may occur), and staging valve position. The fuel pressure
measurement provides information about fuel flowrate and flow
resistance (i.e., potential blockage that may occur).
Interpretation and use of data relating to these sensors is
discussed in further detail below.
[0131] In the depicted embodiment of FIGS. 9 to 12, the burner 310
also has a position sensor or rotation sensor 384 on the staging
valve 348 to detect the percent staging. The rotation sensor 384
could be a Hall effect type sensor, accelerometer type sensor, a
potentiometer, optical sensor, or any other sensor that can
indicate rotational position. Additional position and angle sensors
may be used to determine the position and/or angle of the burner
body 314 relative to the furnace or the burner block 312, and any
other angles or positions that may be relevant to the operation of
the burner 310.
[0132] The instrument enclosure 316 is similar to the instrument
enclosure 16 discussed above, and is sealed and insulated to
protect instrumentation contained therein from the dust and heat of
a furnace environment. The instrument enclosure is positioned
toward the rear 319 of the burner 310 to reduce the radiant heat
energy received from the furnace. The instrument enclosure 316
includes at least a data collector 60, a power supply, and a
transmitter 62 for sending data from the data collector to a data
receiver 200 (which may collect and display data from multiple
burners) located either locally or remotely. A data processor
processes the data from all of the sensors and may be incorporated
into the data collector 60 (e.g., data processor 66), located in
the instrument enclosure 316 separately from the data collector 60
(e.g., data processor 166), or located at a remote location
integral with or separate from the data receiver 200 (e.g., data
processor 266).
[0133] The power supply is used to power the pressure sensors, the
data collector, and the transmitter, and any other sensors and
equipment requiring power. Preferably, the power supply is powered
by a local battery that may or may not be charged via local energy
harvesting or power generation to avoid having to wire outside
power to the instrument enclosure 316. For example, local power
generation may include using temperature gradients, mass flow,
light, induction, or other means to generate sufficient power to
support the sensors and other associated equipment in the
instrument enclosure 316.
[0134] FIG. 8 is a schematic of an exemplary system for handling
the burner data, it being understood that various alternative
combinations of hardware, firmware, and software could be
configured and assembled to accomplish the same functions. One or
more burners 10, 310 may be mounted in the furnace 70, each burner
10, 310 having an instrument enclosure 16, 316, respectively, as
described above. In the schematic of FIG. 8, multiple burners 10,
310 are mounted in the furnace 70. Each instrument enclosure 16,
316 contains a data collector 60 for collecting and aggregating the
data generated by each of the sensors on the burner 10, and a
wireless transmitter 62 for transmitting the data from the data
collector 60, as well as other components such as a power supply
(not shown). The data collector 60 is programmable via one or more
of hardware, firmware, and software, independently or in
combination, to perform application-specific functions. The data
collector 60 may include an integral data processor 66, or a
separate data processor 166 may be located in the instrument
enclosure 16, 316.
[0135] In an exemplary embodiment, the data collector 60 at each
burner 10, 310 aggregates data for that burner 10, 310 using a
highly configurable Wireless Intelligent sensor Node (WIN). The
data collector 60 powers the various sensors associated with the
burner 10, and is programmed to convert a battery voltage of
between 3.2V and 6V, for example to the correct voltage required by
each sensor (e.g., 12V). The battery voltage can be supplied by
locally mounted batteries that are replaceable or that are charged
by local power generation. In one embodiment, the sensors transmit
analog output signals that are read via an analog-to-digital
converter with a programmable gain amplifier to take into account
the output range of each sensor. In another embodiment, the sensors
transmit digital output signals that are scaled, or that may be
scaled, based on the output range of each sensor.
[0136] The data collector 60 is also capable of reading digital
sensors or indicators such as a serial number. An internal
temperature sensor allows monitoring of the ambient temperature and
thus cold junction compensation of thermocouples. An internal
accelerometer allows the attitude of the node (and therefore what
it is attached to) to be measured. Advanced power management is
used to maximize battery life. In particular, the data collector 60
is programmed to power the sensors when measurements are to be
taken, either based on a combination of sensed conditions or on a
regular schedule.
[0137] The sensor measurements are consolidated, taking into
account the gain of the amplifier taken, cold junction
compensation, and any other relevant factors, and transmitted to a
data receiving/processing center 200, preferably via a wireless
link. In an exemplary embodiment, the wireless link uses the 2.4
GHz ISM band and the 802.15.4 standard as its physical layer and
Medium Access Control (MAC). However, any other wireless link now
known or later developed that is suitable for the operating
environment could be used. The protocol uses a star network
topology. Alternative frequencies and protocols are possible,
including without limitation mesh network topologies. The 2.4 GHz
band was chosen since it is a worldwide ISM band while most other
ISM bands are country specific. The wireless link to the node is
bidirectional to allow configuration of the node over the air. The
data may be encrypted prior to transmission for security purposes.
The data may be transmitted directly from the data collector 60 to
the data center 200, or indirectly via one or more Wi-Fi or other
repeaters depending on the distance and signal path between the
burner 10, 310 and the data center 200.
[0138] The data center 200 is configured to receive data from the
individual burners 10, 310, and may also be configured to transmit
data to a cloud-based server which can then serve data, provide
alerts, and perform any other computational function via the
Internet or other network. The data center 200 may be a single
piece of hardware or multiple cooperating pieces of hardware
configured and programmed to perform all of the desired functions
described herein. The data center 200 may also include a data
display (not shown) either at the burner or nearby using an
accompanying piece of hardware that has a display module. The data
center 200 may include, or may be connected to, a data processor
266.
[0139] Electrical power may be supplied to the data collector 60 by
a local power generation system. FIG. 8 shows an exemplary local
power generation system 208 to provide electrical power to the data
center 200. Note that a similar arrangement may also be employed to
provide locally generated electrical power to the data collector
60. In the depicted embodiment, the local power generation system
208 includes a rechargeable battery 206 or super capacitor, and an
energy harvester 204. The rechargeable battery 206 may include, for
example, one or more lithium ion batteries or the like. Charging
and discharging of the battery 206 is controlled by a battery
supervisor 202, which is positioned as a hub between the data
center 200, the battery 206, and the energy harvester 204. The
battery supervisor 202 can be configured to perform various
functions, including but not limited to one or more of the
following, alone or in combination: conditioning power flowing to
and from the battery 206 and the energy harvester 204, maximum
power point tracking to maximize harvested energy efficiency from
the energy harvester 204, and permitting the data collector 60 to
turn on only when there is sufficient energy available in the
battery 206. Local power generation systems 208 as described herein
may be used to respectively power one or more data centers 200,
and/or individual data collectors 60 located at each burner 10, 310
and/or one local power generation system may power one or more
nearby data collectors 60. These local power generation systems can
operate to store power during periods of low usage and release
power during periods of high usage, thereby minimizing the required
capacity of the energy harvester. In addition, similar local power
generation systems 208 can be used to power one or more data
centers 200.
[0140] Advanced power management helps ensure long-term operation
of the system on limited battery or locally generated power supply.
Power is supplied to a Wireless Intelligent sensor Node (WIN) that
is highly configurable to provide the correct required voltage to
each of the different sensors. Moreover, the WIN intelligently
turns off power to individual sensors when they are not in use,
collects data from the sensors when in use, and transmits the data
at configurable time intervals. An indicator light shows the status
of the system and also provides alerts. By powering the sensors
only when they are used (e.g., on a predetermined time rotation to
obtain periodic measurements), this conserves power from the power
supply. However, it has been determined that some sensors,
including but not limited to pressure sensors, may not give
reliable data immediately after being powered up and do not respond
well to being powered for only brief amounts of time. Therefore,
the system requires both careful selection of sensors and specific
configuration of the WIN to match the power up and power down
cycles with the operating requirements of each sensor.
[0141] The data collector 60 receives signals from all the sensors,
and the transmitter 62 sends the collected signal data to a data
indicator where a user can view the status of the various
parameters being measured. The data collector 60 may also include a
data processor 66 or 166, or may send the collected signal data via
the transmitter to a separate data processor 266.
[0142] Measuring the various temperatures, pressures, and positions
of the burner and its components and feed streams and inputs from
the other associated equipment including flow control skids,
separately and in combination, can provide valuable information
that enables an operator to perform preventive maintenance only
when needed and to avoid costly unexpected failures or shutdowns.
In one embodiment, position sensors can include GPS or other local
triangulation position indicators to determine the installation
location of a burner and/or its components. Alternatively, and any
presently known or newly developed method may be used to determine
location.
[0143] In one example of an oxy-oil burner, high oil tip
temperature along with higher than expected oil pressure and
atomizing gas pressure may indicate that the oil nozzle is clogged
or is starting to clog. This alerts an operator that maintenance
should be performed soon so that the tip does not burn up in hot
furnace. As shown in FIG. 19, the tip temperature may indicate a
need for nozzle cleaning better than pressures alone. In the
illustrated example, oil pressure and atomizing air pressure are
monitored in addition to the tip temperature before and after
nozzle cleaning. While the tip temperature increases fairly
uniformly, the pressure changes are not as clear with time, thereby
making it more difficult to determine the need for oil nozzle
cleaning based on pressures alone. After cleaning of the oil nozzle
the tip temperature drops dramatically and the pressures change as
well. However relying on tip temperature alone may not be reliable
since there are other factors that affect tip temperature in
addition to lance nozzle lifetime. For example, FIG. 20 shows the
results of monitoring lance tip temperature while changing the
oxygen staging level for an oxy-oil burner. Here the direct
correlation between the staging level and the tip temperature is
apparent. Therefore multiple pieces of information are preferred
for a reliable interpretation of the data. By combining the staging
level, lance history, pressures, and temperatures, it is possible
accurately determine when the oil nozzle needs to be cleaned.
[0144] The lance or fuel nozzle tip temperature may also be an
indicator of combustion stability or the proximity of the flame
root to the burner. However, as noted above, a knowledge of other
burner conditions is important to accurately interpret the possible
cause of a change in fuel nozzle temperature.
[0145] The difference between the oil inlet pressure and atomizing
gas inlet pressure can provide an estimate of the expected firing
rate, since for a given firing rate, there would be an expected
pressure difference between the oil and atomizing gas. However,
this estimate of firing rate may be affected by clogging as seen in
FIG. 19. Alternatively, or in combination with measuring the
difference between the oil and atomizing gas pressures, the oxygen
inlet pressure and staging valve position can be used to calculate
the firing rate based on an assumed stoichiometry, and this
measurement is not typically affected by oil nozzle clogging. So
for any firing rate, if the pressure difference between the oil and
atomizing gas is more than expected (taking into account the oil
viscosity based on the measured oil temperature and known or
assumed composition), this is an indication that some clogging is
occurring and maintenance is needed.
[0146] FIG. 6 compares the pressure difference between the oil
inlet and the atomizing gas inlet pressures as a function of firing
rate for a known composition of fuel oil at three different oil
temperatures. In all cases, the atomizing nozzle was clean and
unobstructed. As can be seen from the data, the pressure difference
is greater at all firing rates for the lower temperature oil, with
the pressure difference becoming larger in both absolute and
relative terms at the higher firing rates. Testing has shown that
this pressure difference is a much better indicator of the health
of the atomizing nozzle than the oil inlet pressure alone.
[0147] FIG. 7, on the same axes as FIG. 6, compares three
situations at 175.degree. F.: the triangular data points represent
a first fuel and are the same data as the triangular data points on
FIG. 6; the circular data points represent a second fuel having a
more viscous composition at the same temperature conditions with a
clean atomizing nozzle; and the diamond data points represent the
first fuel but flowing through a partially obstructed atomizing
nozzle. It can clearly be seen that the second fuel, due to its
higher viscosity, exhibits a significantly higher pressure
difference (between the oil inlet pressure and the atomizing gas
pressure) than the lower viscosity first fuel, and that the
pressure difference rises significantly when the atomizing nozzle
is partially obstructed or clogged.
[0148] Additionally, the diamond shaped data point in the top right
of the graph occurred during a temperature excursion of the
atomizing nozzle when the temperature had unexpectedly changed,
thereby showing that multivariable monitoring that takes into
account secondary effects can also be useful as an internal check
on the proper operation of all of the sensors and the system.
[0149] Further, using any estimate of firing rate (however
determined) provides an expected oil pressure. If the oil pressure
is higher than the expected oil pressure then either some clogging
is occurring or the oil viscosity is lower than expected. A higher
than expected oil pressure combined with the oil inlet temperature
would help determine whether the oil viscosity is low or if the oil
nozzle is partially blocked.
[0150] If the oil pressure is as expected and the inlet oil
temperature is as expected, than a higher tip temperature may
indicate that the tip is inserted farther than design or that the
flame is not where it is expected to be (see below for an example).
Therefore, it is clear that there is a complex interplay between
the various measured parameters to ascertain, for example, the
reason for an elevated tip temperature or a lower than expected oil
pressure or a higher than expected oil pressure. Note that, in
addition to comparing these parameters on each burner, for example
versus historical or predicted data, these parameters can also be
compared across burners to detect abnormal operation of one of the
burners and can be combined with other plant data. This
determination can include a multi-variable analysis, for example as
described in "A New Paradigm in Real Time Asset Monitoring and
Fault Diagnosis," Neogi, D., et al., 2013 AIChE Annual Meeting,
Conference Proceedings Presentation No. 268b (Nov. 5, 2013).
[0151] In another example, a higher than expected oxidant pressure
or increased fluctuations in pressure may indicate a decrease in
the oxidant flow area in the burner block. For example, FIG. 15
shows data for oxidant pressure with and without an obstruction,
and indicates that the pressure fluctuations with an obstruction
are about 2 to about 6 times the magnitude of the pressure
fluctuations without an obstruction. In addition, the average
oxygen pressure is also higher with an obstruction than
without.
[0152] The expected oxidant pressure can be determined by other
measured variables including flow control skid data. The oxidant
pressure is a function of oxidant flow (or to a first
approximation, firing rate for a known stoichiometry) and staging
valve position as shown in FIG. 16. By estimating the oxidant flow
based on the measured oil pressure (assuming a clean oil nozzle) or
natural gas pressure or from the method described above, there is
an expected oxidant pressure based on the staging valve position.
To more accurately determine the expected oxidant pressure, it may
be useful to also determine the oxidant flow rate, for example via
an oxidant flowmeter or to infer the oxidant flow rate using the
burner firing rate (which may be determined using previously
described methods) and stoichiometry or by measuring the pressure
drop across a known flow restriction device 334 as shown in FIG.
11.
[0153] If the oxidant pressure is higher than the expected oxidant
pressure, that could indicate that the flow area of the oxidant is
decreased either due to blockage of the burner block openings or
some other opening. The burner block openings may be partially
blocked by run down on the block face, slag, or other material that
may have splashed or dripped onto the burner block. If such partial
blockage occurs undetected, it may lead to failure of the burner
and/or burner block, so it is important to detect before such
failure occurs.
[0154] In another example showing the affects of obstructions, FIG.
14 shows natural gas and oxygen pressure in addition to burner
nozzle tip temperature, both with and without an obstruction near
the hot face of the burner block. In this example, the obstruction
was placed near the hot face of the burner block three different
times, denoted as D4, D5, and D6. In each case the nozzle tip
temperature decreased (an unexpected result considering that the
burner flame was impinging on the obstruction at the block exit)
and the natural gas pressure and oxidant pressure both
increased.
[0155] In a similar example in FIG. 13, obstructions were placed
near the hot face of the burner three different times at two
different firing rates, denoted as D1 at a high firing rate FR1,
and D2 and D3 at a lower firing rate FR2. When compared with FIG.
14, a similar result is seen for the first two obstructions D1 and
D2, but for the third obstruction D3 the detected nozzle tip
temperature initially decreased and then increased. It has been
noticed that the directional change of the nozzle tip temperature
is dependent on the operating conditions of the burner and the
furnace that is being fired into. Therefore it is advantageous to
use more than one sensor to identify that there are obstructions
impeding the normal operation of the burner.
[0156] In another example, one or more temperatures sensors mounted
near the face of the burner block or near the gas flow path can be
used to detect flame deflection, for example by comparing burner
block temperatures above and below the exit of the oxidant and
fuel, or to the left and right of the exit of the oxidant and fuel.
These measurements may be particularly useful with regard to the
top (primary oxidant and fuel) exit as compared with the secondary
oxidant exit. FIG. 18C shows temperature measurements in a burner
block for a misaligned burner firing. In this example three
thermocouples were embedded in the burner block positioned at three
different distances from the block hot face: front, middle, and
rear. The measured temperature increased for all three locations
when impingement began. The magnitude of the temperature increased
was a function of the position of the actual flame impingement,
demonstrating the value of multiple temperature measurements for
positively identifying flame impingement in the incipient stages
and as soon as possible.
[0157] In another example, the staging valve position by itself may
be used to determine that the burner settings are optimized and
that operators/engineers are aware when something has changed on
the burner settings. Typically, the staging valve position is set
during startup or commissioning to optimize burner performance for
the particular furnace and process. The staging valve position
would not normally be changed after startup. However, sometimes a
staging valve may be accidentally or intentionally turned to a
non-optimal position, and it would be important to identify such a
condition to ensure that the burner is operating as desired.
[0158] In another example, the inlet oil temperature and possibly
density may be used to estimate the oil viscosity at the atomizing
nozzle. The viscosity is dependent on composition of the oil, so
inlet oil temperature by itself cannot determine the viscosity, but
it can provide information about the viscosity especially when
combined with the inlet oil pressure (a function of the viscosity)
and possibly density. This will let an operator know if the inlet
temperature is appropriate and when combined with the pressure
data, possibly if the oil composition has changed.
[0159] In another example, position and angle sensors can provide
information about the orientation of the burner and whether it is
installed properly, including whether the burner is level or at a
desired slope or angle with respect to a furnace wall. For this
purpose an accelerometer, gyroscope, or other device or
combinations of devices can be used to determine the installation
angle of the burner or parts of the burner. Knowing the burner
angle with respect to the burner wall, as well as possibly other
relevant angles that describe the position of the burner and/or
burner block (e.g., the angle of furnace wall, the burner block, a
burner mounting device or devices) can be used to help determine if
the burner is installed properly. Misalignment of the burner could
cause premature burner or burner block failure. For example, as
shown in FIG. 17B, the angle of the burner with respect to the
burner block and mounting plate was varied in both the pitch and
roll directions, the burner was fired to check for flame
impingement on the burner block. As used herein, pitch indicates
rotation about an axis perpendicular to the longitudinal axis of
the burner, so that the hot face the burner is pivoted up or down
with respect to the rear of the burner; and roll indicates rotation
about an axis coincident with the longitudinal axis of the burner,
so that the plane of the burner face remains the same as the burner
is rotated about its axis (see FIG. 17A). When the burner nozzle
was mounted parallel with the flow passage in the burner block, no
flame impingement was seen. When the angle of the burner nozzle was
out of parallel by about 2 degrees flame impingement occurred.
[0160] In another example, monitoring may help optimizing operating
conditions of the burner to reduce pollutant formation such as
nitrogen oxides (NOx) and to maximize flame quality by reducing or
eliminating sooting.
[0161] The present invention is not to be limited in scope by the
specific aspects or embodiments disclosed in the examples which are
intended as illustrations of a few aspects of the invention and any
embodiments that are functionally equivalent are within the scope
of this invention. Various modifications of the invention in
addition to those shown and described herein will become apparent
to those skilled in the art and are intended to fall within the
scope of the appended claims.
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