Virtual Sensor for Combustion Furnace

A method for operating a furnace using a virtual gas sensor, comprising:

• providing a furnace comprising a first input comprising feed materials configured to be heated in the furnace, a second input comprising an oxygen-containing stream, and a third input comprising a fuel-containing stream;
• providing a virtual sensor comprising a model that determines a combustion product in the furnace, the model generated using inputs comprising condition data, the condition data comprising operating conditions of the furnace collected by a physical gas sensor previously arranged in the furnace;
• placing the virtual sensor in communication with the furnace such that the virtual sensor is configured to receive further condition data associated with operating conditions of the furnace;
• operating the furnace by a combustion reaction created by combining the oxygen from the oxygen-containing stream and the fuel from the fuel-containing stream, the combustion reaction heating the feed materials in the furnace, wherein during operation of the furnace:
• the virtual sensor receives the further condition data;
• in response to receiving the further condition data, the virtual sensor, using the model, determines the combustion product based on the further condition data;
• and
• based on the determined combustion product, the virtual sensor sends a signal to the furnace to automatically adjust a flow rate of at least one of the first input, the second input, and the third input.