Integrated sensor system and methods for combustion processes

An integrated sensor system for use in a furnace system including a furnace having a flue and at least one burner, the furnace containing a charge and having walls bounding a furnace environment, the walls including at least one of a side wall, an end wall, and a roof, the furnace having two or more zones each differently affected by at least one furnace parameter regulating energy input into the furnace, the integrated sensor system comprising:

• a first temperature sensor positioned to measure a first temperature in the furnace;
• a second temperature sensor positioned to measure a second temperature in the furnace, wherein the second temperature sensor responds less rapidly to changes in the furnace environment than the first temperature sensor;
• and
• a controller programmed to:
• receive signals from the first and second temperatures sensors indicative of the first and second measured temperatures, respectively;
• adjust operation of a furnace system parameter based on a relationship between the first and second temperatures, wherein the furnace system parameter includes at least one of a burner firing rate, a burner stoichiometry, a burner staging, a firing rate distribution among two or more burners, a staging distribution among two or more burners, and a furnace pressure, thereby differentially regulating energy input into at least two of the zones of the furnace;
• control energy input into the furnace based on a signal from the second temperature sensor;
• and
• control energy distribution into the furnace based on a signal from the first temperature sensor;
• wherein the relationship between the first and second temperatures is a function of one or more of a difference between the two temperatures, a ratio of the two temperatures, and a weighted average of the two temperatures.