Method for providing oxygen combustion with enhanced staged oxygen control and apparatus therefor

Abstract

A method for providing automatically enhanced staged oxygen combustion in a glass furnace includes providing two or more burner assemblies, each burner assembly being positioned to provide a flame in the glass furnace. Each combustor assembly includes: a combustor body having a primary gas inlet in fluid communication with a gas source through a primary gas valve and a staged injector subassembly; the staged injector subassembly has a secondary gas inlet in fluid communication with a gas source through a secondary gas valve. The primary gas valve and the secondary gas valve are automatically controlled to alternate the total gas flow between a first total gas flow condition and a second total gas flow condition to provide enhanced staged oxygen combustion, the first total gas flow condition having a secondary gas flow rate at a secondary gas flow rate maximum, and the second total gas flow condition having a secondary gas flow rate at a secondary gas flow rate maximum. The second total gas flow condition has a secondary gas flow rate at a secondary gas flow rate minimum.

Description

Technical Field

[0001] The present disclosure relates generally to methods of oxygen combustion, and more particularly to methods and apparatus for oxygen combustion providing automatic enhanced staged oxygen control. Background Art

[0002] Oxyfuel combustion is the process of burning a fuel using oxygen as the primary oxidant instead of air. The use of oxyfuel combustion reduces harmful environmental emissions because the nitrogen component of the air oxidant is eliminated, reducing nitrogen oxide (NOx) emissions and reducing fuel consumption. Oxyfuel combustion is used, for example, in glass furnaces in glass melting processes.

[0003] The first burner used in oxy-fuel combustion in the glass melting process was the conical flame or "tube-in-tube" burner. The development of the flat flame burner improved flame coverage, reduced fuel usage, and provided reduced NOx emissions due to low fuel and oxygen velocities. The crown burner was developed and used in low-boron glass fibers or boron-free glass fibers. However, this technology could not be transferred to other glasses due to divergence problems when the flame hit the glass surface.

[0004] The flat flame burner is then enhanced by (1) staging the oxygen flow to individual ports in the burner and burner block and (2) using preheated fuel within the burner to produce a high brightness flame. Both of these techniques result in further reductions in NOx emissions and reduced fuel use.

[0005] Due to the high cullet ratio and cullet quality issues, further burner improvements are needed for container glass to enhance melting and reduce foam in the furnace. In addition, oxyfuel combustion produces higher concentrations of moisture, which leads to higher foam formation. To minimize these effects, staged oxygen is moved to the top of the burner. In addition, other burners with separate ports for fuel and oxygen are provided to increase fuel close to the glass and reduce combustion conditions. Summary of the invention

[0006] The present disclosure generally relates to methods of oxygen combustion, and more specifically to methods and apparatus for providing oxygen combustion with enhanced staged oxygen control. Applicants have recognized and appreciated that it is beneficial to completely separate the staged oxygen from the primary burner. The burner designs and methods contemplated herein (including or omitting staged) provide improvements in the airflow through the burner, thereby producing a thicker and more evenly distributed flame than a conventional flat flame burner. Conventional methods for controlling staged oxygen involve manually setting the staged oxygen at the burner based on the valve setting at the burner, and the setting is fixed. The methods and systems of the present disclosure allow for automatic control of the amount of staged gas (such as oxygen) provided during the glass melting process. Automatic control of the amount of staged gas allows pulses of staged gas to produce changes in carbon monoxide (CO) and pressure on the glass surface and glass foam to minimize the secondary foam produced, thereby improving the overall oxygen-fuel combustion glass melting process.

[0007] One aspect of the present disclosure relates to a method for providing automatically enhanced staged oxygen combustion in a glass melting furnace. The method includes providing two or more burner assemblies, each of which is positioned to provide a flame in the glass melting furnace. Each of the two or more burner assemblies includes a burner body, the burner body includes a primary gas inlet for receiving a primary gas flow from a gas source, the primary gas inlet is connected to the gas source fluid through a primary gas flow control valve, the primary gas flow control valve is configured to adjust the primary gas flow rate of the primary gas flow, and a staged injector subassembly, the staged injector subassembly includes a secondary gas inlet, the secondary gas inlet is used to receive a secondary gas flow from the gas source, the secondary gas inlet is connected to the gas source fluid through a secondary gas flow control valve, and the secondary gas flow control valve is configured to adjust the secondary flow rate of the secondary gas flow. The total gas flow of each of the two or more burner assemblies is provided by the primary gas flow and the secondary gas flow. The primary airflow control valves and the secondary airflow control valves of at least two of the two or more burner assemblies are automatically controlled by a combustion control computing device so that the total airflow of at least two of the two or more burner assemblies alternates between a first total airflow condition having a secondary gas flow rate at a maximum secondary gas flow rate and a second total airflow condition having a secondary gas flow rate at a minimum secondary gas flow rate to provide enhanced staged oxygen combustion.

[0008] According to an embodiment, the secondary gas flow rate maximum is in the range from about 10% to about 70% of the total gas flow.

[0009] According to an embodiment, the secondary gas flow rate minimum value is less than the secondary gas flow rate maximum value.

[0010] According to an embodiment, the secondary gas flow rate maximum value and the secondary gas flow rate minimum value are different values ​​for each of at least two burner assemblies of the two or more burner assemblies.

[0011] According to an embodiment, the automatic control of the method further includes controlling the primary airflow control valve and the secondary airflow control valve by the combustion control computing device to provide a first total airflow condition within a first time period; and controlling the primary airflow control valve and the secondary airflow control valve by the combustion control computing device to provide a second total airflow condition after the first time period has passed.

[0012] According to an embodiment, the first time period is based on at least one condition within the glass melting furnace.

[0013] According to an embodiment, the at least one condition within the glass melting furnace comprises a batch profile or a furnace temperature.

[0014] According to an embodiment, the first time period is a fixed value.

[0015] According to an embodiment, the first time period is variable.

[0016] According to an embodiment, the first time period is based on a position of at least one of the two or more burner assemblies in the glass melting furnace or an amount of fuel for at least one of the two or more burner assemblies.

[0017] Another aspect of the present disclosure relates to a system for providing automatically enhanced staged oxygen combustion in a glass melting furnace. The system includes two or more burner assemblies, each of which is positioned to provide a flame in the glass melting furnace. Each of the two or more burner assemblies includes a burner body, the burner body includes a primary gas inlet, the primary gas inlet is used to receive a primary gas flow from a gas source, the primary gas inlet is connected to the gas source fluid through a primary gas flow control valve, the primary gas flow control valve is configured to adjust the primary gas flow rate of the primary gas flow, and a staged injector subassembly, the staged injector subassembly includes a secondary gas inlet, the secondary gas inlet is used to receive a secondary gas flow from the gas source, the secondary gas inlet is connected to the gas source fluid through a secondary gas flow control valve, and the secondary gas flow control valve is configured to adjust the secondary flow rate of the secondary gas flow. The total gas flow of each of the two or more burner assemblies is provided by the primary gas flow and the secondary gas flow. A combustion control computing device is coupled to the primary gas flow control valve and the secondary gas flow control valve of each of the two or more burner assemblies. The combustion control computing device includes a memory coupled to a processor, the processor being configured to execute programmed instructions included and stored in the memory to automatically control primary airflow control valves and secondary airflow control valves of at least two of the two or more burner assemblies so that the total airflow of at least two of the two or more burner assemblies alternates between a first total airflow condition having a secondary gas flow rate at a maximum secondary gas flow rate and a second total airflow condition having a secondary gas flow rate at a minimum secondary gas flow rate to provide enhanced staged oxygen combustion.

[0018] According to an embodiment, the secondary gas flow rate maximum is in the range from about 10% to about 70% of the total gas flow.

[0019] According to an embodiment, the secondary gas flow rate minimum value is less than the secondary gas flow rate maximum value.

[0020] According to an embodiment, the secondary gas flow rate maximum value and the secondary gas flow rate minimum value are different values ​​for each of at least two burner assemblies of the two or more burner assemblies.

[0021] According to an embodiment, the processor is configured to execute additional programmed instructions to: control the primary airflow control valve and the secondary airflow control valve to provide a first total airflow condition within a first time period; and control the primary airflow control valve and the secondary airflow control valve to provide a second total airflow condition after the first time period has passed.

[0022] According to an embodiment, the first time period is based on at least one condition in the glass melting furnace.

[0023] According to an embodiment, the at least one condition within the glass melting furnace comprises a batch profile or a furnace temperature.

[0024] According to an embodiment, the first time period is a fixed value.

[0025] According to an embodiment, the first time period is variable.

[0026] According to an embodiment, the first time period is based on a position of at least one of the two or more burner assemblies in the glass melting furnace or an amount of fuel for at least one of the two or more burner assemblies.

[0027] It should be recognized that all combinations of the foregoing concepts and the additional concepts discussed in more detail below (provided such concepts are not mutually inconsistent) are contemplated as being part of the inventive subject matter disclosed herein. In particular, all combinations of the claimed subject matter appearing at the end of this disclosure are contemplated as being part of the inventive subject matter disclosed herein. It should also be understood that terms appearing in any disclosure that is expressly adopted herein and that may also be incorporated by reference should be accorded a meaning that is most consistent with the specific concepts disclosed herein. BRIEF DESCRIPTION OF THE DRAWINGS

[0028] The foregoing will become apparent from the following more particular description of exemplary embodiments of the present disclosure as illustrated in the accompanying drawings, in which like reference numerals refer to the same parts throughout the different views. The drawings are not necessarily drawn to scale, emphasis instead being placed upon illustrating the embodiments of the present disclosure.

[0029] Figure 1 is a partial schematic diagram and a partial block diagram of an enhanced staged oxygen control (ESOC) combustion system according to aspects of the present disclosure.

[0030] Figure 2 is a side view of a burner and block assembly according to aspects of the present disclosure.

[0031] Figure 3 is a top view of a flat flame burner subassembly and a flat flame burner block according to aspects of the present disclosure.

[0032] Figure 4 is a side view of a gas nozzle and a fuel nozzle according to aspects of the present disclosure.

[0033] Figure 5A is a front view of a gas nozzle and a fuel nozzle according to aspects of the present disclosure.

[0034] Figure 5B is a rear view of a gas nozzle and a fuel nozzle according to aspects of the present disclosure.

[0035] Figure 6is a side view of a burner and block assembly according to aspects of the present disclosure.

[0036] Figure 7 is a front perspective view of a staged injector subassembly according to aspects of the present disclosure.

[0037] Figure 8 is a side view of a staged injector subassembly and a staged injector block according to aspects of the present disclosure.

[0038] Fig.9A is a rear side view of a staged injector subassembly and a staged injector block according to aspects of the present disclosure.

[0039] Fig. 9B is a top view of a staged injector subassembly and a staged injector block according to aspects of the present disclosure.

[0040] Fig. 10A is an elevation view of a staged injector subassembly according to aspects of the present disclosure.

[0041] Fig. 10B is a side view of a staged injector subassembly according to aspects of the present disclosure.

[0042] Fig.11 is a front perspective view of a staged injector block according to aspects of the present disclosure

[0043] Fig. 12A is a front view of a staged injector block according to aspects of the present disclosure.

[0044] Fig. 12B is a rear view of a staged injector block according to aspects of the present disclosure.

[0045] Fig.13A is a top cross-sectional view of a staged injector block according to aspects of the present disclosure.

[0046] Fig. 13B is a side partial cross-sectional view of a staged injector block according to aspects of the present disclosure.

[0047] Fig.14A is a side view of a block and burner assembly according to aspects of the present disclosure.

[0048] Fig. 14B is a side view of a block and burner assembly according to aspects of the present disclosure.

[0049] Fig.15 is a block diagram of a combustion control computing device according to aspects of the present disclosure.

[0050] Fig.16is a flow chart of an exemplary method of providing oxygen combustion with enhanced staged oxygen control according to aspects of the present disclosure. DETAILED DESCRIPTION

[0051] The present disclosure generally relates to methods of oxygen combustion, and more specifically to methods and apparatus for providing oxygen combustion with enhanced staged oxygen control. A system for providing automatically enhanced staged oxygen combustion includes two or more burner assemblies, each of the two or more burner assemblies including: a burner body having a first or primary gas inlet, the first or primary gas inlet being configured to receive a primary gas flow having an adjustable primary gas flow rate; and a staged injector subassembly having a second or secondary gas inlet, the second or secondary gas inlet being configured to receive a secondary gas flow having an adjustable secondary gas flow rate. The system also includes a combustion control computing device, the combustion control computing device being coupled to a primary gas flow control valve and a secondary gas flow control valve of each of the two or more burner assemblies, the combustion control computing device being configured to: automatically control the primary gas flow control valve and the secondary gas flow control valve of at least two of the two or more burner assemblies. Automatically controlling the total gas flow of at least two of the two or more burner assemblies alternates between a first total gas flow condition and a second total gas flow condition to provide enhanced staged oxygen combustion. The first total gas flow condition includes a secondary gas flow rate maximum value for the secondary gas flow rate. The second total gas flow condition includes a secondary gas flow rate minimum value for the secondary gas flow rate. A method for providing automatically enhanced staged oxygen combustion includes providing two or more burner assemblies, and automatically controlling a primary gas flow control valve and a secondary gas flow control valve by a combustion control computing device so that the total gas flow alternates between a first total gas flow condition having a secondary gas flow rate at a secondary gas flow rate maximum value and a second total gas flow condition having a secondary gas flow rate at a secondary gas flow rate minimum value to provide enhanced staged oxygen combustion.

[0052] The following is a description of an exemplary embodiment of the present disclosure.Although the block and burner assembly shown in the figures are shown in an upward orientation, the description of the assembly shown in the figures is not intended to be limited to a particular orientation.

[0053] exist Figure 1An example of an environment 10 including an enhanced staged oxygen control (ESOC) combustion system 12, a fuel source 14, a gas source 16, and one or more communication networks 18 is shown in FIG. In this particular example, the ESOC system 12 includes a block and burner assembly 100 having a flat flame burner body 110 having a first or primary gas inlet 112 and a first fuel inlet 114 and a staged injector subassembly 104 positioned separately and above the flat flame burner body 110, the staged injector subassembly having a secondary gas inlet 134, although the block and burner assembly 100 may also include other types and / or numbers of elements, as described in further detail below.

[0054] The ESOC system 12 further includes a primary gas flow meter 20(1), a secondary gas flow meter 20(2), a fuel flow meter 20(3), a primary airflow control valve 22(1), a secondary airflow control valve 22(2), a fuel flow control valve 22(3), and a combustion control computing device 24, although the ESOC system 12 may also include other types and / or numbers of elements and / or other combinations of other elements, including additional electronic devices, such as analog-to-digital converters, etc., and additional blocks and burner assemblies and associated flow meters and valves. The ESOC system 12 advantageously provides automatic control of the amount of staged gas, such as oxygen, provided during the glass melting process. Automatic control of the amount of staged gas allows pulses of staged gas to produce changes in CO and pressure on the glass surface and glass foam, thereby minimizing the generation of secondary foam, thereby improving the overall oxy-fuel combustion glass melting process.

[0055] Although in Figure 1 1 and 2, a single block and burner assembly 100 is shown, but it should be understood that the ESOC system 12 may be used in an oxyfuel combustion furnace (such as a glass furnace) having a pair of block and burner assemblies or having multiple block and burner assemblies by way of example only. In one example, the ESOC system 12 is incorporated into a glass furnace having multiple block and burner assemblies having pairs of block and burner assemblies that fire directly across from each other or in a staggered arrangement along the length of the glass furnace.

[0056] exist Figure 2-14B An exemplary block and burner assembly 100 that may be used in an ESOC system 12 is shown in , although the methods disclosed herein may be used with other blocks and burner assemblies that have separate inlets for staged gas and primary gas to the block and burner assembly. Figure 2A side view of a block and burner assembly 100 according to the present disclosure is shown. The block and burner assembly 100 includes a flat flame burner subassembly 102 and a staged injector subassembly 104. The block and burner assembly 100 also includes a flat flame burner block 106 arranged to receive at least a portion of the flat flame burner subassembly 102 and a staged injector block 108 arranged to receive the staged injector subassembly 104. In one example, the flat flame burner block 106 includes a top surface TS and a bottom surface BS ( Figure 14A-14B As will be appreciated, the flat flame burner block 106 and the staged injector block 108 may be made of highly thermally insulating materials, such as refractory ceramic materials or any other material capable of insulating the heat generated during the combustion process described below. As will be discussed in detail below, the flat flame burner subassembly 102 is arranged to receive gas from the gas source 16 ( Figure 1 ) and fuel source 14( Figure 1 ) of gas 120( Figure 6 ) and fuel 122 ( Figure 6 ) and produces combustion within the flat flame burner block 106. The flat flame burner subassembly 102 can be removably fixed to the flat flame burner block 106 via at least one clamp ring C, such as Figure 2-Figure 3 Furthermore, as will be discussed in greater detail below, the staged injector subassembly 104 and the staged injector block 108 may be separate from the flat flame burner subassembly 102 and the flat flame burner block 106 .

[0057] The flat flame burner subassembly 102 includes a flat flame burner body 110. The flat flame burner body 110 is intended to be a single unitary body made of stainless steel (e.g., 303, 304, or 310 grade stainless steel) and may have a plurality of apertures arranged to receive the various components discussed below that engage with the flat flame burner body 110. In one example, the components discussed below are integral with the flat flame body 110 or may be secured to the apertures by a friction fit. In addition, the apertures may have embossed or molded female or male helical threads that are arranged to receive complementary female or male threads of the various components that engage with the flat flame burner body 110, as will be described below. The flat flame burner subassembly 102 further includes a first gas inlet 112, a first fuel inlet 114, a first gas nozzle 116, and a first fuel nozzle 118 ( Figure 3 In addition, Figure 2 , Figure 6 and Figure 14A-14B As shown, the flat flame burner body 110 may also be arranged to engage with a flat flame burner subassembly support bracket SB secured to the flat flame burner block 106 to support the weight of the flat flame burner subassembly 102 during operation.

[0058] like Figure 3 As shown, the figure shows a top view of the flat flame burner subassembly 102 and the flat flame burner block 108, and the first gas inlet 112 is arranged to engage with the flat flame burner body 110 in at least one of the above-mentioned ways, and is also arranged to engage with the gas source 16 ( Figure 1 ) fluid is connected so that the gas 120 ( Figure 6 1 and 120. The first gas inlet 112 is provided to the flat flame burner body 110 (shown in FIG. 1 ). The first gas inlet 112 is intended to be a tubular member and may be made of stainless steel (e.g., 303, 304, or 310 grade stainless steel). It should be understood that the first gas inlet 112 may be of any size or form sufficient to provide an appropriate volume of gas 120 to the flat flame burner body 110 and subsequently to the first gas nozzle 116, as will be described below. The gas 120 is intended to be oxygen or a gas mixture containing a majority of oxygen. It should be understood that other gas mixtures may be used, for example, a gas mixture containing oxygen or any other gaseous oxidant that supports the combustion process.

[0059] The first fuel inlet 114 is arranged to engage with the flat flame burner body 110 in at least one of the above-described ways and is also arranged to engage with the fuel source 14 ( Figure 1 ) fluid is connected so that the fuel 122 ( Figure 6 ) is provided from the fuel source 14 into the first fuel inlet 114 and into the flat flame burner body 110. Similar to the first gas inlet 112 as above, the first fuel inlet 114 is intended to be a tubular member and can be made of stainless steel (e.g., 303, 304, or 310 grade stainless steel). It should be understood that the first fuel inlet 114 can take any size or form sufficient to provide an appropriate volume of fuel 122 into the flat flame burner body 110 and subsequently to the first fuel nozzle 118 discussed below. The fuel 122 can be selected from: methane, propane, butane, hydrogen, natural gas, carbon monoxide, any combination of the above, or any other gaseous fuel that can self-ignite at high temperatures.

[0060] like Figure 3As shown, the first gas nozzle 116 includes a first end 124 and a second end 126. It should be understood that the first end 124 is arranged to engage with the flat flame burner body 110 in any of the above-mentioned ways. For example, the first end 124 can have an outer circumferential surface having threads machined thereon, which are arranged to engage with complementary threads machined onto the flat flame burner body 110. These threads can have different thread counts, that is, the number of threads per inch, and can vary from a low thread count to a high thread count, the low thread count having the advantage of being cheaper to manufacture at the expense of precision, and the high thread count having the disadvantage of increased manufacturing costs. The second end 126 of the first gas nozzle 116 is arranged so that it terminates or ends at a first distance D1 measured from the flat flame burner body 110 in a first direction DR1 relative to the flat flame burner body 110. In addition, the first gas nozzle 116 also includes a through hole arranged to extend from the first end 124 to the second end 126 along the length of the first gas nozzle 116.

[0061] In addition, the flat flame burner subassembly 102 also includes a first fuel nozzle 118. The first fuel nozzle 118 includes a first end 128 and a second end 130. It should be understood that the first end 128 is arranged to engage with the flat flame burner body 110 in any of the above-described ways. In addition, as shown, the first end 128 of the first fuel nozzle 118 is arranged to be fixed to the first fuel inlet 114, and the first fuel inlet 114 is arranged to extend through a cavity formed in the flat flame burner body 110. For example, the first end 128 may have an outer circumferential surface having threads machined thereon, the threads being arranged to engage with complementary threads machined on the flat flame burner body 110 or the first fuel inlet 114. These threads may have different thread counts, i.e., the number of threads per inch, and may vary from a low thread count, which has the advantage of being cheaper to manufacture at the expense of precision, to a high thread count, which has the disadvantage of increased manufacturing costs. The second end 130 of the first fuel nozzle 118 is arranged such that it terminates or ends at a second distance D2 measured from the flat flame burner body 110 in a first direction DR1 relative to the flat flame burner body 110, wherein the second distance D2 is greater than the first distance D1. It should also be understood that, although not shown, the flat flame burner subassembly 102 can be arranged such that the first gas nozzle 116 and the first fuel nozzle 118 terminate at the same distance relative to the flat flame burner body 110, for example, wherein the first distance D1 in the first direction DR1 is equal to the second distance D2. Figure 2 and Figure 3 As shown, the first fuel nozzle 118 at least partially circumferentially surrounds the throughbore of the first gas nozzle 116 .

[0062] Given that Figure 4-5B The following description should be understood. Figure 4 A side view of the flat flame burner subassembly 102 is shown. Figure 5A and Figure 5B The front and rear views of the first gas nozzle 116 and the first fuel nozzle 118 are shown, respectively. Figure 4-5B As shown, the first gas nozzle 116 has a first end 124 and a second end 126, wherein the first end 124 is disposed adjacent to the flat flame burner body 110 when the first end 124 is secured within the flat flame burner subassembly 102. At the first end 124 of the first gas nozzle 116, the nozzle orifice has a first height H1 and a first width W1. In the example, the orifice disposed at the first end 124 of the first gas nozzle 116 is circular and has a first height H1 between 75 mm and 130 mm (approximately 3 inches and 5 inches), and has a first width W1 also between 75 mm and 130 mm (approximately 3 inches and 5 inches). It should be understood that the nozzle orifice at the first end 124 of the first gas nozzle 116 may be of any shape and have any size to provide an appropriate volume of gas 120 ( Figure 6 ). At the second end 126 of the first gas nozzle 116, the nozzle orifice has a second height H2 and a second width W2, wherein the second height H2 is less than the first height H1, and the second width W2 is greater than the first width W1. In one example, the second height H2 is approximately 40 mm-65 mm (approximately 1.5 inches-2.5 inches), and the second width W2 is approximately 150 mm-175 mm (approximately 6 inches-7 inches). The conical nozzle shape as described above operates to funnel and reshape the gas flow of the gas 120 as it exits the second end 126 of the first gas nozzle 116 ( Figure 6 ), such that the gas 120 is uniformly provided across the second width W2 and mixed with the fuel 122 to facilitate combustion, as will be described below.

[0063] In addition, the first fuel nozzle 118 has a first end 128 and a second end 130, wherein the first end 128 is disposed adjacent to the flat flame burner body 110 when the first end 128 is secured within the flat flame burner subassembly 102. At the first end 128 of the first gas nozzle 116, the nozzle orifice has a third height H3 and a third width W3. In the example, the orifice disposed at the first end 128 of the first fuel nozzle 118 is circular and has a third height H3 between 50 mm and 75 mm (approximately 2 inches and 3 inches), and has a third width W3 also between 50 mm and 75 mm (approximately 2 inches and 3 inches). It should be understood that the nozzle orifice at the first end 128 of the first fuel nozzle 118 may be of any shape and have any size to provide an appropriate volume of fuel 122 ( Figure 6 ). At the second end 130 of the first fuel nozzle 118, the nozzle orifice has a fourth height H4 and a fourth width W4, wherein the fourth height H4 is less than the third height H3, and the fourth width W4 is greater than the third width W3. In one example, the fourth height H4 is approximately 10 mm-40 mm (approximately 0.5 inches-1.5 inches), and the fourth width W4 is approximately 115 mm-165 mm (approximately 4.5 inches-6.5 inches). The conical nozzle shape as described above operates to cause the fuel 122 flow ( Figure 6 ) is funneled and reshaped so that the fuel 122 is evenly provided across the fourth width W4 and mixes with the gas 120 to facilitate combustion, as will be described below.

[0064] like Figure 6 As shown, during operation, gas 120 is allowed to flow through primary gas flow control valve 22 (1) ( Figure 1 ) controlled primary gas flow rate from gas source 16 ( Figure 1 ) flows to the first gas inlet 112 of the flat flame burner body 110. The gas 120 is forced to flow from the flat flame burner body 110 in a first direction DR1 and within the first gas nozzle 116. The gas 120 flows circumferentially outward from the first fuel nozzle 118 and from a first end 124 to a second end 126 of the first gas nozzle 116. The tapered transition from the first height H1 and first width W1 to the second height H2 and second width W2 of the first gas nozzle 116 shapes the gas 120 as it exits the second side 126 of the first gas nozzle 116 for combustion within the flat flame burner block 106. At the same time, the fuel 122 is allowed to flow at a speed controlled by the fuel flow control valve 22(3)( Figure 1 ) controls the fuel flow rate from the fuel source 14 ( Figure 1) flows to the first fuel inlet 114 of the flat flame burner body 110. The fuel 122 is forced to flow from the first fuel inlet 114 in the first direction DR1 and within the first fuel nozzle 118. The fuel 122 flows within the first fuel nozzle 118 from the first end 128 to the second end 130. The tapered transition from the third height H3 and the third width W3 of the first fuel nozzle 118 to the fourth height H4 and the fourth width W4 shapes the gaseous fuel 122 as the gaseous fuel exits the second end 130 of the first fuel nozzle 118 to burn within the flat flame burner block 106. The tapered transition of the first gas nozzle 116 and the first fuel nozzle 118 produces combustion with a flame having a flat shape, i.e., the flame is substantially flat and spans the width of the through hole in the flat flame burner block 106. The flat flame shape results in a higher fuel efficiency for the entire burner system.

[0065] Given that Figure 7-10B The following description should be understood. Figure 7 A front perspective view of the staged injector subassembly 104 is shown. Figure 8 is a side view of the staged injector subassembly 104 secured to the staged injector block 108 . Fig.9A and Fig. 9B 1 and 2 show a rear view and a top view, respectively, of the staged injector subassembly 104 secured to the staged injector block 108. Similarly, Fig. 10A and Fig. 10B A front view and a side view of the staged injector subassembly 104 are shown, respectively. The staged injector subassembly 104 includes a staged injector body 132. The staged injector body is intended to be a single, unitary body made of stainless steel (e.g., 303, 304, or 310 grade stainless steel) and may have a plurality of apertures arranged to receive various components discussed below that engage with the staged injector body 132. In one example, the components discussed below are integral with the staged injector body 132 or may be secured to the apertures via a friction fit. Additionally, the apertures may have embossed or molded female or male helical threads that are arranged to receive complementary female or male threads of various components that engage with the staged injector body 132, as will be described below.

[0066] The staged injector body 132 further includes a second gas inlet 134, a staged injector nozzle 136, a flange 138, and at least one half coupling 140. The second gas inlet 134 is arranged to receive gas from the gas source 16 ( Figure 1 ) by the secondary gas control valve 22 (2) ( Figure 1 ) controls the secondary gas flow rate of the gas 120. The second gas inlet 134 is arranged to be connected to the staged injector body 132 in at least one of the above-mentioned ways, and is also arranged to be connected to the gas source 16 ( Figure 1 ) fluid is connected so that the gas 120 ( Figure 6 108) is provided into the second gas inlet 134 and the staged injector body 132. The second gas inlet 134 is intended to be a tubular member and may be made of stainless steel (e.g., 303, 304, or 310 grade stainless steel). It should be understood that the second gas inlet 134 may take any size or form sufficient to provide an appropriate volume of gas 120 into the staged injector body 132 and subsequently into the staged injector nozzle 136, as will be described below. The staged injector nozzle 136 is disposed at one end of the staged injector body 132 and is arranged to slidably engage with a recess 150 (discussed below) of the staged injector block 108, so that the gas 120 provided within the staged injector body 132 can flow from the staged injector body 132 to a plurality of gas channels 154A-154C (discussed below) of the staged injector block 108. In addition, to allow the staged injector nozzle 136 to sit flush within the recess 150, the staged injector body 132 also includes a flange 138 that is circumferentially arranged around at least a portion of the staged injector nozzle 136 and is arranged to contact a first side 142 of the staged injector block 108 during operation of the block and combustor assembly 100 (discussed below). The flange 138 may include through holes or apertures that are arranged to receive fasteners or bolts such that the bolts can secure the flange 138 and subsequently the staged injector body 132 to the staged injector block 108. It should be understood that other fasteners may be used, including but not limited to bolts, screws, or retaining rings, for example, as described above. Figure 2-Figure 3 In addition, the staged injector body 132 may further include a half coupling 140, which is arranged on at least a portion of the staged injector body 132 or passes through at least a portion of the staged injector body 132. It should be understood that the half coupling 140 can be arranged to be connected to an external device, such as but not limited to a pressure gauge, a flow meter, etc.

[0067] As discussed above, the staged injector body 132 of the staged injector subassembly 104 is arranged to be removably secured to the staged injector block 108. Figure 11-13B, which respectively illustrate a perspective view, a front view, a rear view, a top view, and a side view of the staged injector block 108, the staged injector block 108 having a first side 142, a second side 144, a top surface 146, and a bottom surface 148. Near the first side 142, the staged injector block 108 includes a recess 150 and a fastener recess 152. Although the recess 150 is illustrated as a rectangular recess, it should be understood that the recess 150 may be of any size or take any shape that is complementary to the shape of the staged injector nozzle 136, such that at least a portion of the staged injector nozzle 136 extends into the recess 150. In addition, as discussed above, the staged injector block 108 may also include one or more fastener recesses 152 that are arranged to receive fasteners, such as bolts or screws, through through holes in the flange 138 of the staged injector subassembly 104.

[0068] The staged injector block 108 further includes a plurality of gas passages 154A-154C (collectively referred to as "a plurality of gas passages" or "a plurality of gas passages 154"), which are arranged within and through the staged injector block 108 and are arranged to span from the first side 142 of the staged injector block 108 to the second side 144 of the staged injector block 108. In addition, the staged injector block 108 also includes a plurality of orifices 156A-156F (collectively referred to as "a plurality of orifices" or "a plurality of orifices 156"). As shown in FIG. Fig. 12A and Fig. 12B As shown, each of the plurality of gas channels 154 includes two orifices, one proximate to the first side 142 and one proximate to the second side 144. Thus, the first side 142 includes three orifices 156A-156C of the plurality of orifices 156, and the second side 144 includes three orifices 156D-156F, i.e., two orifices per channel. In one example, gas channel 154A begins at orifice 156A near the first side 142 and terminates at orifice 156F near the second side 144. Similarly, gas channel 154B begins at orifice 156B near the first side 142 and terminates at orifice 156E at the second side 144. Finally, gas channel 154C begins at orifice 156C near the first side 142 and terminates at orifice 156D near the second side 144.

[0069] In one example, if Figure 12A-12B and Fig. 13BAs shown, each of the plurality of gas channels 154 is arranged at a downward pitch or angle such that each gas channel is inclined from the first side 142 to the second side 144 in the direction of the flat flame burner block 106. In other words, the orifice (e.g., orifices 156A-156C) of each gas channel arranged adjacent to the first side 142 is arranged at a first orifice distance AD1 from the bottom surface 148 of the staged injector block 108 (or from the flat flame burner block 106, because the bottom surface 148 and the flat flame burner block are arranged to contact each other during operation). In addition, the orifice (e.g., orifices 156D-156F) of each gas channel arranged adjacent to the second side 144 is arranged at a second orifice distance AD2 from the bottom surface 148 of the staged injector block 108 (or from the flat flame burner block 106), wherein the second orifice distance AD2 is less than the first orifice distance AD1. The difference in the orifice distances of the first and second groups of orifices creates a gas passage that slopes downward, ie, slopes from the first side 142 to the second side 144 in the direction of the flat flame burner block 106 .

[0070] In another example, each of the plurality of gas channels 154 is arranged at a different radial angle relative to each other, that is, arranged non-parallel to each other. Fig.13A As shown, the gas passage 154B is arranged substantially parallel to an imaginary central axis A arranged from the first side 142 to the second side 144 of the staged injector block 108. Fig.13AAs shown, the gas passage 154A is arranged at a first radial angle RA1 relative to the imaginary central axis A and the gas passage 154C is arranged at a second radial angle RA2. In one example, the first radial angle RA1 and the second radial angle RA2 are selected from a range of 1 degree-20 degrees relative to the central axis A, or more specifically, from a range of 5 degrees-8 degrees, or even more specifically 6.47 degrees. In one example, the first radial angle RA1 and the second radial angle RA2 are selected so that the gas passages 154A and 154C flare outward at appropriate radial angles relative to the central axis A as the gas passages travel from the first side 142 to the second side 144, so that the gas 120 leaving each gas passage is provided at a position that substantially matches the width of the flat flame (e.g., the second width W2 of the flat flame nozzle 116) produced by the flat flame burner subassembly 102 as discussed above. After initial combustion through the flat flame burner subassembly 102, the availability of this additional staged gas 120 improves the efficiency of the overall block and burner system 100. In addition, the ability to individually adjust the secondary gas flow (i.e., the gas flow 120 passing through the staged injector subassembly 104 and entering the staged injector block 108) allows for enhanced flame control of the flat flame produced by the flat flame burner subassembly 102, as described in further detail below. In one example, the ratio and flow rate of the gas 120 passing through the staged injector subassembly 104 can be adjusted using the secondary gas control valve 22(2) to increase or decrease the length of the flame produced by the system, and / or to increase or decrease the width of the flame produced within the through hole of the flat flame burner block 106.

[0071] The staged arrangement of the block and burner assembly 100 allows for adjustment and / or splitting of the ratio of gas 120 to fuel 122 in order to improve the burner efficiency of the combustion produced by the flat flame burner subassembly 104, as described with respect to the examples discussed below. In one example, the ratio of gas 120 to fuel 122 combusted by the flat flame burner subassembly is 1:1, while the remainder of the gas 120 is provided by the staged injector subassembly 104. By providing additional staged gas through the plurality of gas passages 154 as discussed above, the overall efficiency and control of the flame produced by the system can be controlled with increased precision.

[0072] In this example, the staged injector block 108 is arranged to sit on top of the flat flame burner block 106 (e.g., in contact with the top surface TS) during operation of the block and burner assembly 100. A bracket 158 ​​or other mechanism is arranged between the flat flame burner block 106 and the staged injector block 108 to secure the blocks to each other and prevent them from moving relative to each other during operation. In this embodiment, the arrangement of the staged injector block 108 on top of the flat flame burner body 106 is advantageous for providing enhanced combustion to reduce secondary foaming during glass melting, as described in the embodiments below.

[0073] The aforementioned block and burner system (e.g., block and burner assembly 100) has several advantages. First, the flat flame burner subassembly 102 produces a flat flame during the combustion process discussed above, which improves overall burner efficiency. Second, the aforementioned block and burner assembly allows for enhanced control of the flat flame produced in the flat flame burner subassembly 102 by allowing precise control of the staged gases through the staged injector subassembly 104 and the staged injector block 108. Third, because the materials used for the flat flame burner block 106 and the staged injector block 108 are generally brittle and prone to cracking during repeated combustion operations, the aforementioned block and burner assembly 100 allows for independent replacement and / or repair of each portion of the block, i.e., the flat flame burner block 1086 or the staged injector block 108. In addition, making the two blocks separable as described above prevents cracks that start in one block from traveling to the other block. Finally, the first gas nozzle 116 and the first fuel nozzle 118 of the flat flame burner subassembly 102 are arranged to extend a first distance D1 from the body of the subassembly and a second distance D2 from the body of the subassembly, respectively, wherein the first distance D1 is less than or equal to the second distance D2. This nozzle arrangement prevents the gas 120 from the first gas nozzle 116 from mixing with the fuel 122 from the first fuel nozzle 118 before it leaves the flat flame burner subassembly. The external mixing of the gas 120 and the fuel 122 helps prevent backflow and reduce the operating temperature of the subassembly.

[0074] See again Figure 1In this example, the first gas inlet 112 of the flat flame body burner 110 is in fluid communication with the gas source 16 through the first gas flow meter 20 (1) and the primary gas flow control valve 22 (1) for receiving the primary gas flow from the gas source 16. The second gas inlet 134 of the staged injector subassembly 104 is in fluid communication with the gas source 16 through the secondary gas flow meter 20 (2) and the secondary gas flow control valve 22 (2) for receiving the secondary gas flow from the gas source 16, thereby providing a separate staged gas inlet. In this example, the second gas inlet 134 is located above the first gas inlet 112 during operation of the block and burner assembly 100. The first fuel inlet 114 of the flat flame burner body 110 is in fluid communication with the fuel source 14 through the fuel flow meter 20 (3) and the fuel flow control valve 22 (3) for receiving the fuel flow from the fuel source.

[0075] Each of the flow meters 20(1)-20(3) is operably coupled to the combustion control computing device 24 via one or more communication networks 18 to provide flow readings to control the computing device 24. The flow meters 20(1)-20(3) can be any flow meter configured to measure the flow of a fluid known in the art. The control valves 22(1)-22(3) are also operably coupled to the combustion control computing device 24 via one or more communication networks 18 so that the combustion control computing device 24 can provide instructions to control the operation of the control valves 22(1)-22(3) to control the flow of gas or fuel provided to the block and burner assembly 100. The control valves 22(1)-22(3) can be any control valve configured to operably regulate the flow of a fluid provided to the various inlets of the block and burner assembly 100.

[0076] See now Fig.15 In this example, the combustion control computing device 24 includes one or more processors 40, a memory 42, and a communication interface 44 coupled together via a bus 46 or other communication link, but the combustion control computing device 24 may include other types and / or numbers of elements in other configurations.

[0077] The processor 40 of the combustion control computing device 24 can execute programmed instructions stored in the memory 42 for any number of functions described and illustrated herein. In one example, the processor 40 receives information from the flow meters 20(1)-20(3) and provides instructions to the flow control valves 22(1)-22(3) to perform the method of automatic enhanced staged oxygen control described herein. The processor 40 may include, for example, one or more CPUs, GPUs, or general purpose processors having one or more processing cores, although other types of processors, such as FPGA devices, may also be used.

[0078] The memory 42 stores these programming instructions for one or more aspects of the present technology as described and illustrated herein, but some or all of these programming instructions may be stored elsewhere. Various different types of memory storage devices, such as random access memory (RAM), read-only memory (ROM), hard disk, solid state drive, flash memory, or other computer readable media that is read and written by a magnetic, optical, or other read-write system coupled to a processor, etc., may be used for the memory.

[0079] Therefore, the memory 42 of the combustion control computing device 24 can store one or more applications or programs, which can include computer executable instructions that, when executed by the processor 40 of the combustion control computing device 24, cause the combustion control computing device 24 to perform the actions described below. The application can be implemented as a module, thread, pipeline, stream, or other component of the application. Further, the application can be implemented as an operating system extension, module, plug-in, etc.

[0080] Further, the application can operate in a cloud-based computing environment. The application can be executed within or as a virtual machine or virtual server that can be managed in a cloud-based computing environment. Moreover, the application can run in one or more virtual machines (VMs) executed on the combustion control computing device 24. The communication interface 44 operably couples and communicates between the combustion control computing device 24 and the flow meters 20(1)-20(3) and the flow control valves 22(1)-22(3). For example, the combustion control computing device 24 can be configured to receive flow data from the flow meters 20(1)-20(3) and provide instructions to operatively control the operation of the control valves 22(1)-22(3), thereby regulating the flow of the block and the burner assembly 100.

[0081] Although an exemplary combustion control computing device 24 is described and illustrated herein, other types and / or numbers of systems, devices, components and / or elements in other topologies may be used. It should be understood that the example systems described herein are for exemplary purposes, as many variations of the specific hardware and software used to implement the examples are possible, as will be appreciated by those skilled in the art.

[0082] In addition, two or more computing systems or devices may replace the combustion control computing device 24. Thus, as desired, the principles and advantages of distributed processing such as redundancy and replication may also be implemented to improve the robustness and performance of the example devices and systems. The examples may also be implemented on a computer system extending across any suitable network using any suitable interface mechanism and service technology, including, by way of example only, any suitable form of long distance telephone service (e.g., voice and modem), wireless service networks, cellular service networks, packet data networks (PDNs), the Internet, intranets, and combinations thereof.

[0083] Examples may also be presented as one or more non-transitory computer-readable media having stored thereon instructions for one or more aspects of the present technology, as described and illustrated by the examples herein. In some examples, the instructions include executable code that, when executed by one or more processors, causes the processors to perform the steps necessary to implement the methods of the examples of this technology described and illustrated herein.

[0084] Now refer to Figure 1-Figure 16 An exemplary method of automatically enhancing staged oxygen combustion is described. Although the method is described with respect to a single block and burner assembly, it should be understood that the method can be performed with respect to other types and / or numbers of burners having separate gas inlets for staged and primary gases. In one example, the described method is performed with at least two burners, each having separate gas inlets for staged and primary gases positioned to provide flames in a glass melting furnace, but the method can be used with any number of burner assemblies.

[0085] First, in step 1000, a set point for the fuel flow from the fuel source 14 to the fuel inlet 114 is determined by the combustion control computing device 24 for each burner assembly employed, such as the block and burner assembly 100. The fuel flow set point is determined based on methods known in the art for the ignition process. The combustion control computing device 24 can be communicatively coupled to a device that provides an internal temperature so that the combustion control computing device 24 can adjust the fuel flow set point based on the internal temperature reading. For example, the fuel flow set point can be based on a temperature control loop in which the fuel flow set point is continuously adjusted based on the internal temperature of the furnace or based on other control settings.

[0086] In step 1002, the combustion control computing device 24 provides instructions to operate the fuel flow control valve 22(3) to match the fuel flow set point. In one example, the combustion control computing device 24 uses data from the fuel flow meter 20(3) to provide adjustments to the fuel flow control valve 22(3). The combustion control computing device 24 provides instructions to the fuel flow control valve 22(3) so that the fuel flow is adjusted based on temperature and other melting characteristics.

[0087] Next, in step 1004, a total oxygen flow set point is determined by the combustion control computing device 24 based on the established ratio between the fuel flow and the gas flow for each burner, or the oxygen ratio set point. By way of example, the oxygen ratio set point may be stored in the memory 42 of the combustion control computing device 24. The oxygen ratio set point may vary from 1.60 to 2.75 and may depend on the type of fuel and heating value, oxygen purity, desired excess oxygen, or other furnace or glass chemistry factors. The total oxygen flow set point may be calculated based on the following equation (1) or any other suitable alternative:

[0088] Total oxygen flow set point = fuel flow * oxygen ratio set point (1)

[0089] In some cases, the gas (e.g., oxygen) may drive the use of the fuel, or alternatively, the fuel may drive the use of the gas (e.g., oxygen). There are many known control schemes for the total fuel flow in a glass furnace and for individual burners, which can be incorporated into the methods disclosed herein. In this example, the total gas flow for each burner in the ESOC system 12 is provided by a combination of a primary gas flow provided from the gas source 16 to the first gas inlet 112 of the burner body 110 and a secondary gas flow provided from the gas source 16 to the secondary (staged) gas inlet 134 in the staged injector subassembly 104.

[0090] The ESOC system 12 advantageously allows for completely separate, automated control of the gas provided to the first gas inlet 112 (primary gas) and to the second gas inlet 134 (staged gas) from the gas source 16. Thus, the total oxygen flow set point determined in step 1004 can then be used to pulse staged oxygen, producing changes in carbon monoxide (CO) and pressure on the glass surface and glass foam, thereby inhibiting and minimizing secondary foam. The staged gas set point is determined based on the staged gas percentage, as given by the following equation (2) or any suitable alternative:

[0091] Staged oxygen set point = total oxygen flow rate * staged oxygen percentage (2)

[0092] The staged gas set point can advantageously be set to a staged set point high (SSPH) value or a staged set point low (SSPL) value by the combustion control computing device 24, as described in further detail below. The SSPH value can be set, for example, between 10% and 70% of the total oxygen, and the SSPL value is less than the SSPH. The SSPH and SSPL values ​​can be set to enhance combustion conditions. Different burners in the glass melting furnace can be set to have different SSPH values ​​and SSPL values, although each burner can be set to have the same SSPH value and SSPL value. The primary oxygen set point is given by the following equation (3) or any suitable alternative:

[0093] Primary oxygen set point = total oxygen flow set point * (1-stage oxygen percentage) (3)

[0094] As described below, the combustion control computing device 24 can provide instructions to control the primary gas flow control valve 22(1) and the secondary gas flow control valve 22(2) to alternate the staged gas flow (i.e., staged oxygen) at the second gas inlet 134 between SSPH values ​​and SSPL values ​​while also maintaining the total oxygen flow by adjusting the amount of gas (i.e., primary oxygen) provided at the first gas inlet 112. The following method improves the overall oxygen / fuel glass melting process.

[0095] In step 1006, the control combustion computing device 24 provides instructions to control the primary gas flow control valve 22(1) and the secondary gas flow control valve 22(2) so that the staged gas (i.e., the amount of gas provided through the second gas inlet 134) is set to SSPH, although in other examples, the staged gas may be initially set to SSPL. The amount of gas provided through the first inlet gas 112 is also adjusted to provide the total oxygen flow set point determined in step 1004 based on equations (2) and (3). At the SSPH value of the staged oxygen provided at the second gas inlet 134 located above the first gas inlet 112 in this example, the block and burner assembly 100 produces higher CO / reducing conditions near the glass surface by diverting more oxygen to the second gas inlet 134. Under SSPH conditions, the flame provided by the block and burner assembly 100 is also longer, covering a larger area on the glass surface.

[0096] The control computing device 24 provides instructions to maintain the SSPH condition as a set of time factors from 1 to a time factor high level (TFHS) value. In one example, the TFHS value is variable and controlled by the combustion computing device 24, and can be based on data related to one or more conditions in the gas furnace, including batch characteristic curves monitored by CCTV or other equipment, furnace temperatures measured by thermocouples, infrared or other equipment. In another example, the TFHS value is fixed. The TFHS value can also vary with each burner in the glass furnace controlled by the ESOC system 12. For example, the TFHS value of each burner may depend on the position of the burner in the furnace and / or the amount of fuel in the burner, but the TFHS value can also be based on other factors.

[0097] After the TFHS value has been reached, in step 1008, the control combustion computing device 24 provides instructions to control the primary gas flow control valve 22(1) and the secondary gas flow control valve 22(2) so that the staged gas (i.e., the amount of gas provided through the second gas inlet 134) is set at the SSPL and the amount of gas provided through the first inlet gas 112 is also adjusted to provide the total oxygen flow set point determined based on equations (2) and (3) in step 1004. At the SSPL value of the staged oxygen provided at the second gas inlet 134, the block and burner assembly 100 produces lower CO / reducing conditions near the glass surface when oxygen is diverted from the second gas inlet 134 to the first gas inlet 112 of the block and burner assembly 100.

[0098] The control computing device 24 provides instructions to maintain the SSPL condition as a set of time factors from 1 to a time factor low level (TFLS) value. In one example, the TFLS value is variable and controlled by the combustion computing device 24, and can be based on data related to one or more conditions in the gas furnace, including a batch characteristic curve monitored by CCTV or other equipment, a furnace temperature measured by a thermocouple, infrared or other equipment. In another example, the TFLS value is fixed. The TFLS value can also vary with each burner in the glass furnace controlled by the ESOC system 12. For example, the TFLS value of each burner may depend on the position of the burner in the furnace and / or the amount of fuel on the burner, but the TFHS value can also be based on other factors.

[0099] In step 1010, the combustion control computing device 24 alternates between steps 1006 and 1008 to control the primary gas flow control valve 22(1) and the secondary gas flow control valve 22(2) to provide a pulsed staged oxygen level that automatically varies between SSPH and SSPL at the second gas inlet 134. The cycling between SSPH to SSPL creates pulses in the more reducing gas near the glass surface. The pulses also cause pressure conditions near the glass surface to change as the flame near the glass changes from a high staged condition to a low staged condition.

[0100] Although the operation of a single burner is described, the ESOC system 12 of the present disclosure can be used to control at least two burners in a glass melting furnace, although other numbers of burners can also be controlled using the disclosed ESOC system 12. In addition, the method can be used in a glass melting furnace with a burner that has a fixed staging gas percentage or no staging. In this method, the total combustion is controlled by always ensuring that the total oxygen ratio is at or above the stoichiometric ratio. In this scheme, it is feasible to operate some burners in a glass melting furnace below the stoichiometric ratio as long as some burners are set to above the stoichiometric ratio to ensure complete combustion.

[0101] Therefore, the present disclosure provides systems and methods for providing automatic enhanced staged oxygen combustion. More specifically, the system method of the present disclosure provides automatic control of the amount of staged gas, such as oxygen, provided during the glass melting process. Automatic control of the amount of staged gas allows pulsing of the staged gas to produce changes in CO and pressure on the glass surface and glass foam, thereby minimizing the secondary foam generated, thereby improving the overall oxygen-fuel combustion glass melting process.

[0102] It should be understood that in any method claimed herein that includes more than one step or action, the order of the method steps or actions is not necessarily limited to the order in which the method steps or actions are described unless explicitly indicated to the contrary.

[0103] All definitions, as defined and used herein, should be understood to control over dictionary definitions, definitions in documents incorporated by reference, and / or ordinary meanings of the defined terms.

[0104] Unless explicitly stated to the contrary, the indefinite articles "a" and "an" as used herein in the specification and claims should be understood to mean "at least one".

[0105] As used herein in the specification and claims, the phrase "and / or" should be understood to mean "either or both" of the elements so combined, i.e., elements that are present in combination in some cases and separately in other cases. Multiple elements listed with "and / or" should be interpreted in the same manner, i.e., "one or more" of the elements so combined. Other elements may optionally be present in addition to the elements specifically identified by the "and / or" clause, whether related or unrelated to those elements specifically identified.

[0106] As used herein in the specification and claims, "or" should be understood to have the same meaning as "and / or" as defined above. For example, when separating the items in a list, "or" or "and / or" should be interpreted as inclusive, i.e., including at least one of a plurality of elements or lists of elements, but also including more than one of an element or list of elements, and optionally other unlisted items. Only explicitly indicating the opposite terms, such as "only one" or "exactly one", or when used in the claims, "consisting of..." will refer to including exactly one element in a number of elements or lists of elements. Generally, the term "or" as used herein should only be interpreted as indicating an exclusive alternative (i.e., "one or the other but not two") when there is an exclusive term in front, such as "either", "one", "only one" or "exactly one".

[0107] As used herein in the specification and claims, the phrase "at least one" with respect to a list of one or more elements should be understood to mean at least one element selected from any one or more of the elements in the list of elements, but not necessarily including at least one of each element specifically listed within the list of elements, and not excluding any combination of elements in the list of elements. This definition also allows that elements may optionally be present in addition to the elements specifically specified within the list of elements to which the phrase "at least one" refers, whether related or unrelated to those elements specifically specified.

[0108] In the claims, as well as in the above description, all transitional phrases, such as "comprising," "including," "carrying," "having," "containing," "involving," "maintaining," "composed of," etc., shall be understood to be open-ended, i.e., meaning including but not limited to. Only the transitional phrases "consisting of" and "consisting essentially of" shall be closed or semi-closed transitional phrases, respectively.

[0109] Although several inventive embodiments have been described and shown herein, it will be readily apparent to those of ordinary skill in the art that various other devices and / or structures for performing the functions described herein and / or obtaining results and / or one or more advantages will be readily apparent to those of ordinary skill in the art, and such changes and / or modifications will each be considered to be within the scope of the inventive embodiments described herein. More generally, it will be readily understood by those skilled in the art that all parameters, dimensions, materials, and configurations described herein are intended to be exemplary, and that actual parameters, dimensions, materials, and / or configurations will depend on one or more specific applications for which the teachings of the present disclosure are used. Those skilled in the art will recognize or be able to determine many equivalents of the specific inventive embodiments described herein using no more than routine experiments. Therefore, it should be understood that the foregoing embodiments are presented only by way of example, and within the scope of the appended claims and their equivalents, the inventive embodiments may be implemented in a manner different from that specifically described and claimed. The inventive embodiments of the present disclosure are directed to each individual feature, system, article, material, and / or method described herein. In addition, if such features, systems, articles, materials, and / or methods are not mutually inconsistent, any combination of two or more such features, systems, articles, materials, and / or methods is included within the scope of the invention disclosed herein.

Claims

1. A method for providing auto-enhanced staged oxygen combustion in a glass melting furnace, the method comprising: Two or more burner assemblies are provided, each burner assembly being positioned to provide a flame in the glass melting furnace, each of the two or more burner assemblies comprising: A burner body, the burner body comprising: a primary gas inlet for receiving a primary gas flow from a gas source, the primary gas inlet being in fluid communication with the gas source via a primary gas flow control valve, the primary gas flow control valve being configured to adjust a primary gas flow rate of the primary gas flow; and a staged injector subassembly, the staged injector subassembly comprising a secondary gas inlet for receiving a secondary gas flow from the gas source, the secondary gas inlet being in fluid communication with the gas source via a secondary gas flow control valve, the secondary gas flow control valve being configured to adjust a secondary flow rate of the secondary gas flow, wherein a total gas flow of each of the two or more burner assemblies is provided by the primary gas flow and the secondary gas flow; and The primary airflow control valve and the secondary airflow control valve of at least two of the two or more burner assemblies are automatically controlled by a combustion control computing device so that the total airflow of the at least two of the two or more burner assemblies alternates between a first total airflow condition having a secondary gas flow rate at a maximum secondary gas flow rate and a second total airflow condition having a secondary gas flow rate at a minimum secondary gas flow rate to provide enhanced staged oxygen combustion.

2. The method according to claim 1, wherein: The secondary gas flow rate maximum is in the range of from about 10% to about 70% of the total gas flow.

3. The method according to claim 1, wherein: The minimum secondary gas flow rate is less than the maximum secondary gas flow rate.

4. The method according to claim 1, wherein: The secondary gas flow rate maximum value and the secondary gas flow rate minimum value are different values ​​for each of the at least two burner assemblies of the two or more burner assemblies.

5. The method according to claim 1, wherein: The automatic control further comprises: controlling the primary airflow control valve and the second airflow control valve by the combustion control computing device to provide the first total airflow condition within a first time period; and The primary airflow control valve and the secondary airflow control valve are controlled by the combustion control computing device to provide the second total airflow condition after the first period of time has elapsed.

6. The method according to claim 5, wherein: The first time period is based on at least one condition in the glass melting furnace.

7. The method according to claim 6, wherein: The at least one condition within the glass melting furnace includes a batch profile or a furnace temperature.

8. The method according to claim 5, wherein: The first time period is a fixed value.

9. The method according to claim 5, wherein: The first time period is variable.

10. The method according to claim 5, wherein: The first time period is based on a location of at least one of the two or more burner assemblies in the glass melting furnace or an amount of fuel for the at least one of the two or more burner assemblies.

11. A system for providing automatically enhanced staged oxygen combustion in a glass melting furnace, the system comprising: Two or more burner assemblies, each burner assembly being positioned to provide a flame in the glass melting furnace, each of the two or more burner assemblies comprising: A burner body, the burner body comprising: a primary gas inlet for receiving a primary gas flow from a gas source, the primary gas inlet being in fluid communication with the gas source via a primary gas flow control valve, the primary gas flow control valve being configured to adjust a primary gas flow rate of the primary gas flow; and a staged injector subassembly, the staged injector subassembly comprising a secondary gas inlet for receiving a secondary gas flow from the gas source, the secondary gas inlet being in fluid communication with the gas source via a secondary gas flow control valve, the secondary gas flow control valve being configured to adjust a secondary flow rate of the secondary gas flow, wherein a total gas flow of each of the two or more burner assemblies is provided by the primary gas flow and the secondary gas flow; and a combustion control computing device coupled to the primary airflow control valve and the secondary airflow control valve of each of the two or more burner assemblies, the combustion control computing device comprising a processor configured to execute programmed instructions to: The primary airflow control valve and the secondary airflow control valve of at least two of the two or more burner assemblies are automatically controlled so that the total airflow of the at least two of the two or more burner assemblies alternates between a first total airflow condition having a secondary gas flow rate at a maximum secondary gas flow rate and a second total airflow condition having a secondary gas flow rate at a minimum secondary gas flow rate to provide enhanced staged oxygen combustion.

12. The system according to claim 11, wherein: The secondary gas flow rate maximum is in the range of from about 10% to about 70% of the total gas flow.

13. The system according to claim 12, wherein: The minimum secondary gas flow rate is less than the maximum secondary gas flow rate.

14. The system according to claim 11, wherein: The secondary gas flow rate maximum value and the secondary gas flow rate minimum value are different values ​​for each of the at least two burner assemblies of the two or more burner assemblies.

15. The system according to claim 11, wherein: The processor is configured to execute additional programming instructions to: controlling the primary airflow control valve and the second airflow control valve to provide the first total airflow condition during a first time period; and The primary air flow control valve and the secondary air flow control valve are controlled to provide the second total air flow condition after the first period of time has elapsed.

16. The system of claim 15, wherein: The first time period is based on at least one condition in the glass melting furnace.

17. The system of claim 16, wherein: The at least one condition within the glass melting furnace includes a batch profile or a furnace temperature.

18. The system of claim 15, wherein: The first time period is a fixed value.

19. The system of claim 15, wherein: The first time period is variable.

20. The system of claim 15, wherein: The first time period is based on a location of at least one of the two or more burner assemblies in the glass melting furnace or an amount of fuel for the at least one of the two or more burner assemblies.

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