DESC:CROSS-REFERENCE TO RELATED APPLICATIONS AND PRIORITY
[001] The present application claims priority from provisional patent application filed on August 14, 2015 having application number 4233/CHE/2015.
TECHNICAL FIELD
[002] The present subject matter described herein, in general, relates to method of chemical dosing in glass melting furnace system and in particular to a method for neutralizing the effects of impurities, in a petroleum coke, upon combustion in a glass manufacturing furnace system.
BACKGROUND
[003] The global demand for natural gas continues to rise. This change in the supply chain has triggered variations in fuel prices across different regions, particularly where they lack a domestic supply of natural gas or where natural gas resources are located in economically inaccessible geological formations. As a result, a strong demand has emerged to use less expensive alternative fuels such as Petroleum coke (petcoke) while meeting stringent environmental regulation targets without compromising glass quality and productivity. However, there are many challenges for the use of alternative fuels in traditional combustion.
[004] Petroleum Coke is the co-product of several processes used in petroleum refining to upgrade “residuum” into gasoline and middle distillate-range fuels. Petroleum coke is typically developed from oil refinery cooker units or other coking processes such as contact coking, fluid coking, flexi-coking and delayed coking. Petroleum coke is a black-colored solid composed primarily of carbon, hydrogen, nitrogen, oxygen and may contain limited amounts of elemental forms of sulphur, metals, and other non-volatile inorganic compounds. A typical composition of petroleum coke is given as: carbon about 90%; hydrogen about 3%; nitrogen from about 2% to 4%; oxygen about 2%; sulphur from about 0.05% to 6%; and others about 1%. Petroleum coke is usually used as fuel for combustion in industrial and power generating plants. In particular, cement plants and power plants are currently the two greatest consumers of petroleum coke.
[005] Glass manufacturing industry relies heavily on natural gas and fuel oil for glass melting. Generally, the glass is manufactured by utilizing different type of furnace and fuels, depending on the type of glass. Conventionally, the fuel used to melt glass is fuel oil, coming from distillation of petroleum such as petroleum coke.
[006] One of the major challenges associated with the use of petroleum coke in glass manufacturing is the presence of sodium, sulphur and vanadium. Generally, vanadium reacts with refractory in the furnace and reduces the life, whereas sulphur deposits in the regenerator to choke the passage of flue gases and air during firing process. The presence of above impurities has a negative effect on the structure of the refractories in the glass melting furnace. The foremost characteristic requirements of a refractory are to withstand exposure to elevated temperature for extended period of time. In addition it must be able to withstand sudden changes in temperature, resist the erosive action of molten glass, the corrosive action of gases, and the abrasive forces of particles in the atmosphere. Even though additives are mixed in the petroleum coke to overcome the side effects of petroleum coke in the process of glass manufacturing such methods lack control and uniformity, thus resulting in uneven combustion of the fuel.
SUMMARY
[007] Before the present method for chemical dosing of petroleum coke with one or more chemical, in a glass manufacturing furnace system, are described, it is to be understood that this application is not limited to the particular system(s), and methodologies described, as there can be multiple possible embodiments which are not expressly illustrated in the present disclosures. It is also to be understood that the terminology used in the description is for the purpose of describing the particular implementations or versions or embodiments only, and is not intended to limit the scope of the present application. This summary is provided to introduce aspects related to method for dosing of petroleum coke with one or more chemical, in a glass manufacturing furnace system. This summary is not intended to identify essential features of the claimed subject matter nor is it intended for use in determining or limiting the scope of the claimed subject matter.
[008] In one implementation, a method for neutralizing the effects of impurities, in a petroleum coke, upon combustion in a glass melting furnace system, may be disclosed. The method may comprise receiving a first chemical and the petroleum coke. The first chemical comprises one or more of silica, calcium, magnesium and aluminum. The method further comprises dosing the petroleum coke with the first chemical. The dosage range of the first chemical with the petroleum coke is in the range of 0-0.25%. Furthermore, the method comprises conveying a dosed petroleum coke to a pneumatic screw pump. The method may moreover comprise receiving the second chemical. The second chemical comprises of calcium hydroxide and the dosage range of the second chemical is based on the quantity of petroleum coke. The method may comprise dosing the dosed petroleum coke with the second chemical in the pneumatic screw pump. The method may moreover comprise of transferring the dosed petroleum coke to one or more burners for combustion, thereby neutralizing the effects of impurities, in a petroleum coke, upon combustion in a glass manufacturing furnace system.
BRIEF DESCRIPTION OF THE DRAWINGS
[009] The foregoing detailed description of a method for chemical dosing of the petroleum coke, with one or more chemical, in a glass manufacturing furnace system is better understood when read in conjunction with the appended drawings. For the purpose of illustrating of the present subject matter, an example of a dosing method of a petroleum coke, with one or more chemical, in a glass manufacturing furnace system is provided as figures; however, the invention is not limited to the specific method and system disclosed in the document and the figures.
[010] In the detailed description, the method for chemical dosing of the petroleum coke, with one or more chemical, in a glass manufacturing furnace system is described in detail with reference to the accompanying figures. In the figures, the left-most digit(s) of a reference number identifies the figure in which the reference number first appears. The same numbers are used throughout the drawings to refer various features of the present subject matter.
[011] Figure 1 illustrates a petroleum coke dosing glass manufacturing furnace system, in accordance with an embodiment of the present subject matter.
[012] Figure 2 illustrates a flow diagram for dosing petroleum coke, in accordance with an embodiment of the present subject matter.
DETAILED DESCRIPTION
[013] Some embodiments of this disclosure, illustrating all its features, will now be discussed in detail. The words "comprising," "having," "containing," and "including," and other forms thereof, are intended to be equivalent in meaning and be open ended in that an item or items following any one of these words is not meant to be an exhaustive listing of such item or items, or meant to be limited to only the listed item or items. It must also be noted that as used herein and in the appended claims, the singular forms "a," "an," and "the" include plural references unless the context clearly dictates otherwise. Although any method for chemical dosing of the petroleum coke, with one or more chemical, in a glass manufacturing furnace system, similar or equivalent to those described herein can be used in the practice or testing of embodiments of the present disclosure, the exemplary, chemical dosing of the petroleum coke, with one or more chemical, in a glass manufacturing furnace system are now described. The disclosed embodiments for chemical dosing of the petroleum coke, with one or more chemical, in a glass manufacturing furnace system are merely examples of the disclosure, which may be embodied in various forms.
[014] Various modifications to the embodiment will be readily apparent to those skilled in the art and the generic principles herein may be applied to other embodiments for chemical dosing of the petroleum coke, with one or more chemical, in a glass manufacturing furnace system. However, one of ordinary skill in the art will readily recognize that the present disclosure for chemical dosing of the petroleum coke, with one or more chemical, in a glass manufacturing furnace system is not intended to be limited to the embodiments described, but is to be accorded the widest scope consistent with the method and features described herein.
[015] In implementation of the present subject matter, method of dosing the petroleum coke, with one or more chemical, to neutralize the effects of impurities in the glass melting furnace system (100), is disclosed. In the implementation, the petroleum coke is dosed with ore more chemicals for neutralization of vanadium present in the petroleum coke. In another implementation, the effects of sulphur on the glass melting furnace system (100) are neutralized upon combustion of the petroleum coke with one or more chemicals. The more or more chemicals maybe one of silica, calcium magnesium, aluminum or calcium hydroxide individually or in combination, to overcome the effects of sulphur, sodium, and vanadium.
[016] In the implementation, the predetermined dosing of the petroleum coke may be at one or more predetermined locations of the glass melting furnace system (100). In one example the petroleum cokes maybe dosed in the pump hopper or the pneumatic screw pump.
[017] Referring now to Figure 1, where the Figure 1 illustrates a glass melting furnace system (100), in accordance with an embodiment of the present subject matter, is disclosed. Further, table 1 below, disclosed some of the elements of glass melting furnace system (100).

Table 1: List of elements
Element Number Definition Element Number Definition
101 Big bag unloading machine 111 Manual slide gate
102, 104, 113 Rotary Air lock feeder 112 Screw conveyor with VFD
103 Rotary screen 118 Return line with valve
105, 114 Pneumatic Screw hopper 119a, 119b Pneumatic Valve
106, 115 Pneumatic screw pump 120 Reversal system
107, 116 Roots blower 121A, 121B Petroleum coke burner
108, 117 Dust collector 122 Air Atomizing root blower
109 Service silo 123 Furnace
110A Single shaft agitator 124 Chimney
110B Single shaft agitator 125 Regenerator
[018] In the embodiment the glass melting furnace system (100) is as follows. The petroleum coke is received at the glass melting furnace system (100) site in jumbo bags of 1 tons (not shown) capacity. In one example, the jumbo bags are unloaded from trucks and stored in closed shed (not shown) near unloading station. The unloading station comprises of big bag unloading machine (101), rotary air lock feeder (102) and (104), rotary screen (103) and a pneumatic screw hopper (105), and pneumatic screw pump (106) for material transfer. The big bag unloading machine (101) is provided with an electric hoist (not shown) to lift the bag from ground level to machine. The operator positions the bags on the big bag unloading machine 101 and material is extracted, which is fed to rotary screen (103) via Rotary Air Lock feeder (102), of unloading machine. A rotary type screen (103) is provided for screening the received petroleum coke to eliminate the foreign bodies and oversize material. The pneumatic screw hopper (105) is provided to collect the screened material. The Pneumatic screw pump (106) is used to convey the material pneumatically to Service silo (109). A Rotary air lock feeder (104) is provided above the pneumatic screw pump to avoid any air leakage or back pressure and to ensure smooth material flow. The pneumatic screw pump (106) conveys the petroleum coke. A twin lobe positive displacement Roots blower (107) is provided for air transportation. The conveyed material is collected in Service silo (109). The complete circuit from unloading machine to pneumatic screw pump has to be suitably vented to ensure dust free atmosphere. The vent points are provided on unloading machine, rotary screen and hopper and connected to the Dust collector (117).
[019] Service silo (109) is positioned near the furnace area. The service silo (109) is provided with extraction system. The silo is also provided with purging system, explosion flaps and bag filter. The single shaft agitator (110A) & (110B) is provided for smooth flow of petroleum coke. The screw conveyer with VFD or dosing screw (112) shall extract the material from service silo (109) and feeds to pump hopper (114) via Rotary Air lock feeder (113). Further, the pump hopper (114) discharges the petroleum coke to pneumatic screw pump (115). A twin lobe positive displacement roots blower (116) is used for conveying air to the pneumatic screw pump (115). The piping arrangement is done to suit furnace requirement. The first pneumatic diverter or reversal system (120) and second pneumatic diverter or return line valve (118) conveys material to service silo 109. Further, the reversal system (120) in an alternating fashion diverts petroleum coke to the pneumatic valves (119a) & (119b). The pneumatic valves are specially designed for high pressure air to the Petroleum coke burners (121A) and (121B). Since petroleum coke has low volatiles it takes longer time to ignite. The burners are provided with swirled to ensure the petroleum coke particles are retained in air stream till it ignites. An additional air atomizing roots blower (122) is considered for burners which will provide the swirl air and also does the function of cooling the burner and retaining the flame. Further the furnace (123) may be connected to a chimney (124) via a flue gas system (not shown).
[020] Various modifications to glass melting furnace system (100) will be readily apparent to those skilled in the art upon reading the description and the generic principles herein may be applied to other embodiments. Furthermore, one of ordinary skill in the art will readily recognize the glass melting furnace system (100) may comprise other systems and machines and the like.
[021] In the embodiment, during operation, a petroleum coke bag in unloaded in the big bag unloading machine (101). Further, the petroleum coke may be transferred to the service silo (109) by the pneumatic screw pump (106). From the service silo (109) the petroleum coke may be further transferred to the pump hopper (114). In one example, the one or more of first chemical may be Silica, Calcium, Magnesium and Aluminum in the pump hopper (114), thus neutralizing the effect of vanadium and saving refractory in the glass melting furnace system (100). The dosage of one or more chemicals may be in a predetermined range varying from 0 to 0.25 %. In one implementation the dosage range of one or more chemical is directly proportional to the percentage presence of Vanadium in petroleum coke.
[022] From the pump hopper (114) the dosed petroleum coke maybe further conveyed to the pneumatic screw pump (115) via screw conveyor with VFD motor (112). In one example, during the flow of petroleum coke in the pneumatic screw pump (115), the petroleum coke is dosed with one or more of second chemical, where the second chemical may be Calcium hydroxide [Ca (OH)2], by a dosing system (not shown). In one embodiment, the quantity of the dosage may be in the range of 1% to 5 % of the petroleum coke quantity.
[023] Various locations for dosing the petroleum coke with Calcium hydroxide, Silica, Calcium, Magnesium and Aluminum in the glass melting furnace system (100) may be readily apparent to those skilled in the art upon reading the description and the generic principles herein may be applied to other embodiments.
[024] Upon dosing of the petroleum coke, the roots blower (116) blows air at low pressure in to pneumatic screw pump (115) for forming the dosed air- petroleum coke mixture. Upon mixing, the dosed air- petroleum coke mixture is transferred to the petroleum coke burners (121A) and (121B), located inside a furnace (123), to generate heat by combustion. Furthermore, the heat generated is utilized for glass melting.
[025] In the embodiment, the dosage of Calcium hydroxide (lime powder) maybe infused into the air- petroleum coke prior to combustion. Further, based on the infusion of Calcium hydroxide, the effects of sulphur are neutralized upon combustion. During the combustion Calcium hydroxide reacts with sulpher dioxide to form calcium sulphate and water.
Ca(OH)2+2So2= CaSo4+ 2H2O ………………………………………………………………………. (1)
Wherein,
Ca(OH)2= Calcium hydroxide
2So2= sulpher dioxide
CaSo4= calcium sulphate
2H2O= Water
[026] In the embodiment, the dosage of group of chemicals, in particular Silica, Calcium, Magnesium and Aluminum is infused into the air- petroleum coke prior to combustion. Further, based on the infusion of Calcium hydroxide, the effects of vanadium are neutralized upon combustion. The following reactions take place during neutralization of vanadium, sodium and sulphur:
S+O2 >>SO2 1/2 O2 >>SO3
Na2O + SO3 >>Na2SO4
28 Na2 SO4 +12 V2 O5 = 2(Na2O. V2O4. 5V2 O5) + 26 Na2 SO4+2SO3+O2
3 Mgo.V2O5 + 3CaO. V2O5……………………………………. (2)

Wherein,
Na2 SO4= Sodium Sulfate
V2 O5= Vanadium Pentoxide
Na2O= Sodium Oxide
V2O4= Vanadium Dioxide
SO3= Sulpher Trioxide
O2=Oxygen
Mgo.V2O5= Magnesium Vanadium Pentoxide
CaO. V2O5= Calcium Vanadium Pentoxide
After neutralization by CaO, MgO, Si2O3 and Al2O3 following products will be generated: 3 MgO.V2O5 and 3 CaO. V2O5.
[027] In one implementation, rat hole formation in the glass melting furnace system (100) is eliminated due to reduction in impurities such a vanadium. Vanadium present in the petroleum coke is responsible for rat hole formation in the superstructure furnace. In one example, the one or more chemical during combustion prevents vanadium to react with the bonding material and refractory of the furnace superstructure by forming a layer under the roof of the furnace.
[028] In another implementation, the sulphur present in the petroleum coke reacts with the one or more third chemical to prevent choking of the regenerator passage during the petroleum coke flue gas flow from the furnace to the chimney. The one or more third chemical maybe one of vanadium oxide, sodium oxide or calcium oxide. In one implementation, the third chemical may be dosed directly into the regenerator (125) to be mixed with the petroleum coke upon combustion. The third chemical is dosed in its pure form. In one example, the third chemical reacts with the sulphur to make the sulphur depositions fragile and collect at the bottom of the regenerator (125). The collected fragments may be cleaned, thus keeping the regenerator (125) and the passage to the checker clean. The following reactions take place:
V2O5 + Na2O = Na2V2O6
V2O5 + CaO = CaV2O6
[029] In an exemplary implementation, the dosing of chemical to the petroleum coke in the glass melting furnace system (100) maybe in a variety of proportions. The dosing of the chemical may vary based on the increase or decrease of the proportion of petroleum coke supply to the burners in the glass melting furnace system (100).
[030] Referring now to Figure 2, a method (200) for neutralizing the effects of impurities, in a petroleum coke, upon combustion in a glass melting furnace system, may be disclosed, in accordance with an embodiment of the present subject matter. The method (200) may be described in the general context of glass melting furnace system.

[031] The order in which the method (200) is described is not intended to be construed as a limitation, and any number of the described method blocks can be combined in any order to implement the method (200) or alternate methods. Additionally, individual blocks may be deleted from the method (200) without departing from the spirit and scope of the subject matter described herein. Furthermore, the method (200) can be implemented in any suitable glass melting furnace systems or combination thereof. However, for ease of explanation, in the embodiments described below, the method (200) may be considered to be implemented in the above described system (100).
[032] At block (202), the first chemical and the petroleum coke is received. In one example, the first chemical and the petroleum coke are received in the service silo (109). Further, first chemical may comprise one or more of silica, calcium, magnesium and aluminum. The first chemical may be used to neutralize vanadium.
[033] At block (204), the first chemical is dosed in the petroleum coke in the range of 0-0.25%. Furthermore, the dosage of first chemical is directly proportional to the percentage of vanadium in petroleum coke. In one example, the first chemical is dosed in the petroleum coke via dosing hopper in the service silo (109).
[034] At block (206), the dosed petroleum coke is conveyed to a pneumatic screw pump (106), (115).
[035] At block (208), the second chemical is received. The dosage of the second chemical is based on the quantity of petroleum coke. In one example, the second chemical may comprise of calcium hydroxide.
[036] At block (210), the dosed petroleum coke is dosed with the second chemical in the pneumatic screw pump (106), (115).
[037] At block (212), the petroleum coke dosed with the first chemical and the second chemical is transferred to one or more burners (121A), (121B), for combustion. In one example the burners (121A), (121B) may be located inside the glass melting furnace system (100). In another example, the effects of the sulphur are neutralized upon combustion. Thereby, neutralizing the effects of impurities, in a petroleum coke, upon combustion in the glass manufacturing furnace system.
[038] Exemplary embodiments discussed above may provide certain advantages. Though not required to practice aspects of the disclosure, these advantages may include below illustrative advantages of dosing a petroleum coke, with one or more chemicals, in a glass melting furnace system to neutralize the effects of impurities.
[039] Some embodiments of the chemical dosing of the petroleum coke in glass melting furnace system enable uniform and effective dosing of the chemical and petroleum coke.
[040] Some embodiments of the chemical dosing in glass melting furnace system enable reduction in sulphur deposits in the regenerator of the glass meting furnace.
[041] Some embodiments of the chemical dosing in glass melting furnace system enable neutralization of the effects of impurities in the furnace of the glass manufacturing furnace system.
[042] Although implementations of chemical dosing in a petroleum coke, with one or more chemical, in a glass manufacturing furnace system have been described in language specific to structural features and/or methods, it is to be understood that the appended claims are not necessarily limited to the specific features or methods described. Rather, the specific features, devices, systems and methods are disclosed as examples of implementations of dosing method for dosing of petroleum coke, with one or more chemical, in a glass manufacturing furnace system.
,CLAIMS:WE CLAIM:

1. A method for neutralizing the effects of impurities, in a petroleum coke, upon combustion in a glass melting furnace system, wherein the method comprising:
receiving, a first chemical and the petroleum coke wherein the first chemical comprises one or more of silica, calcium, magnesium and aluminum;
dosing, the petroleum coke with the first chemical wherein the dosage range of the first chemical with the petroleum coke is in the range of 0 – 0.25%;
conveying, a dosed petroleum coke to a pneumatic screw pump;
receiving, a second chemical wherein the second chemical comprises of calcium hydroxide wherein the dosage range of the second chemical is based on the quantity of the petroleum coke;
dosing, the dosed petroleum coke with the second chemical in the pneumatic screw pump;
transferring, the dosed petroleum coke to one or more burners for combustion thereby neutralizing the effects of impurities, in a petroleum coke, upon combustion in the glass manufacturing furnace system.
2. The method of claim 1, wherein the first chemical is directly proportional to the percentage presence of vanadium in the petroleum coke.
3. The method of claim 1, wherein the petroleum coke is dosed in a pump hopper.
4. The method of claim 1, wherein the second chemical is dosed in the range of 1-5 % of the petroleum coke quantity.
5. The method of claim 1, wherein the method comprises dosing a flue gas generated from the combustion of the petroleum coke with a third chemical; wherein the third chemical comprises one or more of vanadium oxide, sodium oxide and calcium oxide, wherein the third chemical is dosed in a regenerator.