Method of operating a furnace

Patent metadata

Field	Value
Publication number	US-10746470-B2
Application number	US-201815962480-A
Country	US
Kind code	B2
Filing date	Apr 25, 2018
Priority date	Jun 29, 2017
Publication date	Aug 18, 2020
Grant date	Aug 18, 2020

Abstract

A method of operating a furnace having process tubes and multiple burners where it is desired to conform the temperatures of the process tubes to selected target temperature criterion. The present method provides a systematic and quantitative approach to determine how to adjust burner flow rates to result in desired tube wall temperatures, for example, using objective functions to decrease the probability that temperatures pertaining to the plurality of process tubes exceed their selected limit temperatures. An objective function can also be used to reduce the excess oxidant requirement for the furnace.

First claim

We claim:

1. A method of operating a furnace having a plurality of burners, each of the plurality of burners having flow rates associated therewith, the furnace containing a plurality of process tubes, the method comprising:
(a) selecting target temperature criterion pertaining to the plurality of process tubes, wherein the target temperature criterion comprises a first objective function where the first objective function comprises calculated probabilities that temperatures pertaining to the plurality of process tubes exceed respective limit temperatures;
(b) measuring first temperature information comprising data for each of the plurality of process tubes at a first operating condition wherein the first temperature information for the plurality of process tubes is measured by:
capturing a first plurality of images of an interior area of the furnace, at least some images of the first plurality of images being associated with different portions of the interior area of the furnace, wherein each image of the first plurality of images comprises first pixel data associated with a portion of the plurality of process tubes; and
processing a portion of the first pixel data to obtain the first temperature information for the plurality of process tubes;

(c) providing an estimate of a mathematical function characterizing a relationship between burner flow rate changes for two or more of the plurality of burners and individual temperature changes for at least a portion of the plurality of process tubes;
(d) calculating a first target flow rate solution set having solutions for the two or more of the plurality of burners consistent with conforming temperatures of the plurality of process tubes to the target temperature criterion for the plurality of process tubes using the estimate of the mathematical function and the first temperature information for the plurality of process tubes; and
(e) adjusting a first valve upstream of at least one of the two or more of the plurality of burners to change at least one of the flow rates of the two or more of the plurality of burners in accordance with the first target flow rate solution set wherein the first valve is not upstream of all burners of the furnace.

2. The method according to claim 1 wherein the calculated probabilities that temperatures pertaining to the plurality of process tubes exceed respective limit temperatures are determined from the first temperature information.

3. The method according to claim 2 wherein the calculated probabilities that temperatures pertaining to the plurality of process tubes exceed respective limit temperatures are determined from weighted average values (e.g. mean, median, and/or mode) and variances calculated from the first temperature information.

4. The method according to claim 1 wherein the first objective function comprises at least one of a sum, maximum and/or a weighted average value of calculated probabilities that temperatures for the plurality of process tubes exceed respective limit temperatures.

5. The method according to claim 1 wherein the first objective function characterizes one or more of (i) the average mean probability of exceeding the limit temperatures for tube segments at a selected height or length of the process tubes in the furnace, (ii) the average mean probability that the process tubes exceed the limit temperatures for multiple segmented lengths of the process tubes, (iii) the maximum probability that the process tubes exceed the limit temperature for the process tubes, (iv) the average mean probability of exceeding the limit temperatures for the gas-transfer outlet tubes, and (v) the maximum probability that the gas-transfer outlet tubes exceed the limit temperature for the gas-transfer outlet tubes.

6. The method according to claim 1 wherein the target temperature criterion comprises a plurality of objective functions.

7. The method according to claim 6 wherein the plurality of objective functions includes the first objective function comprising calculated probabilities that temperatures for the plurality of process tubes exceed respective limit temperatures and a second objective function not including a calculated probability.

8. The method according to claim 1 wherein the limit temperatures are related to selected process tube design temperature limits.

9. The method according to claim 1 wherein the first objective function comprises calculated probabilities that temperatures pertaining to the plurality of process tubes exceed respective limit temperatures for a tube segment at a selected furnace elevation.

10. The method according to claim 1 wherein the first objective function comprises calculated probabilities that temperatures pertaining to the plurality of process tubes exceed respective limit temperatures of a corresponding plurality of gas-transfer outlet tubes connecting each respective tube of the plurality of process tubes to a collection header.

11. The method according to claim 1 wherein the furnace has an exhaust for withdrawing a combustion product gas stream and comprises a plurality of oxygen concentration sensors operatively disposed to sense the oxygen concentration in the combustion product gas stream, the plurality of oxygen concentration sensors spatially positioned to detect oxygen concentration changes responsive to changes in the flow rates of individual burners or groups of burners, the method further comprising:
selecting target oxygen concentration criterion pertaining to the plurality of oxygen concentration sensors;
measuring first oxygen concentration information comprising data for each of the plurality of oxygen concentration sensors at the first operating condition;
providing an estimate of a second mathematical function characterizing a relationship between burner flow rate changes for two or more of the plurality of burners and individual oxygen concentration changes for the plurality of oxygen concentration sensors; and
calculating a first excess oxygen-related target flow rate solution set having solutions for the two or more of the plurality of burners consistent with conforming oxygen concentrations measured by the plurality of oxygen concentration sensors to the target oxygen concentration criterion for the plurality of oxygen concentration sensors using the estimate of the second mathematical function and the first oxygen concentration information;
wherein the first valve upstream of at least one of the two or more of the plurality of burners is adjusted to change at least one of the flow rates of the two or more of the plurality of burners in accordance with the first target flow rate solution set and the first excess oxygen-related target flow rate solution set.

12. The method according to claim 11 wherein the first valve is adjusted in accordance with the first target flow rate solution set and the second target flow rate solution set using a weighting function for the first target flow rate solution set and the second target flow rate solution set.

Assignees

• Air Prod & Chem
• Air Prod & Chem

Inventors

• Esmaili Ali
• Li Hu
• Labuda Matthew James
• Isom Joshua David

Classifications

• F27D21/0014

  Devices for monitoring temperature · CPC title

• C01B2203/169

  Controlling the feed · CPC title

• F27D19/00 Primary

  Arrangements of controlling devices · CPC title

• C01B2203/1223

  Methanol · CPC title

• F27D21/02

  Observation or illuminating devices · CPC title