DESC:
FORM 2

THE PATENTS ACT, 1970
(39 of 1970)
&
THE PATENT RULES, 2003

COMPLETE SPECIFICATION
(See Section 10 and Rule 13)

Title of invention:
PETCOKE FLOW CONTROL

Applicant:
HSIL Limited
A company Incorporated in India under the Companies Act, 1956
Having Address:
Glass Factory Road,
Off. Motinagar, Sanathnagar P.O.
Hyderabad - 500 018, Telangana State, India.

The following specification particularly describes the invention and the manner in which it is to be performed.
TECHNICAL FIELD
[001] The present subject matter described herein, in general, relates to a method and system for implementing in glass manufacturing furnace system and in particular a method and a system for controlling a petcoke-air ratio in a glass manufacturing furnace system.
BACKGROUND
[002] Petroleum coke (Petcoke) is a black-colored solid composed primarily of carbon, and may contain sulfur, metals, and non-volatile inorganic compounds. Petcoke is delivered from oil refinery cooker units or other cracking processes. Coking processes that can be employed for making petcoke include contact coking, fluid coking, flexi-coking and delayed coking. Petcoke typically is 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 petcoke.
[003] Generally, manufacturing of glass is done based utilizing different type of furnace and using different types of fuels, dependent on the final characteristics of the glass product and also with regard to the thermal efficiency of the processes. Conventionally, the fuel used to melt glass is fuel oil, coming from distillation of petroleum. However, the continuing upward spirals of energy costs, for example natural gas, have forced use of petcoke in manufacturing of glass. During the manufacturing of glass the control of flow of pet coke is important as an uneven flow of petcoke and uneven petcoke air-mixture may result in low quality of glass. Further, petcoke used in manufacturing of glass is generally in form of fine dust particles, thus conventional flow measurement devices fail to control the flow of petcoke, when implemented in a glass manufacturing furnace system.
SUMMARY
[004] Before the present system(s) and method for controlling a petcoke-air ratio 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 a system and a method for controlling a petcoke-air ratio 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.
[005] In one implementation, the flow monitoring and control system for controlling a petcoke-air ratio in a glass manufacturing furnace system is disclosed. In one embodiment, the flow monitoring and control system may comprise a memory, and a processor coupled to the memory. Further, the processor may be capable of executing instructions to perform steps. In the embodiment the system may obtain sensor data associated with one or more sensors located in a glass manufacturing furnace system. The sensor data may comprise frequency, temperature data and amplitude data associated with a petcoke-air mixture flowing through the glass manufacturing furnace system. Upon obtaining, the flow monitoring and control system may compute a petcoke-air mixture flow rate, a petcoke-air ratio and a petcoke flow rate based on the sensor data and generate a petcoke-air mixture flow rate variance, a petcoke-air ratio variance and a petcoke flow rate variance. Further, the petcoke-air mixture flow rate variance is generated based on a comparison of the petcoke-air mixture flow rate with a predefined petcoke-air mixture flow rate, the petcoke-air ratio variance is generated based on a comparison of the petcoke-air ratio with a predefined petcoke-air ratio, and the petcoke flow rate variance is generated based on a comparison of the petcoke flow rate with a predefined petcoke flow rate. Subsequent to generating, the flow monitoring and control system may alter a speed of a variable frequency drive motor coupled to a screw conveyers and roots blower based on the petcoke-air mixture flow rate variance, the petcoke-air ratio variance and the petcoke flow rate variance thereby controlling the petcoke-air ratio in the glass manufacturing furnace system.
[006] In another implementation, a method for controlling a petcoke-air ratio in a glass manufacturing furnace system is disclosed. In one embodiment, the method may comprise obtaining sensor data associated with one or more sensors located in a glass manufacturing furnace system. The sensor data may comprise frequency, temperature data and amplitude data associated with a petcoke-air mixture flowing through the glass manufacturing furnace system. Further, the method may comprise computing a petcoke-air mixture flow rate, a petcoke-air ratio and a petcoke flow rate based on the sensor data and generating a petcoke-air mixture flow rate variance, a petcoke-air ratio variance and a petcoke flow rate variance. The petcoke-air mixture flow rate variance may be generated based on a comparison of the petcoke-air mixture flow rate with a predefined petcoke-air mixture flow rate, the petcoke-air ratio variance may be generated based on a comparison of the petcoke-air ratio with a predefined petcoke-air ratio, and the petcoke flow rate variance may be generated based on a comparison of the petcoke flow rate with a predefined petcoke flow rate. The method may furthermore comprise altering a speed of a variable frequency drive motor coupled to a screw conveyers and roots blower based on the petcoke-air mixture flow rate variance, the petcoke-air ratio variance and the petcoke flow rate variance thereby controlling the petcoke-air ratio in the glass manufacturing furnace system.
BRIEF DESCRIPTION OF THE DRAWINGS
[007] The foregoing detailed description of embodiments is better understood when read in conjunction with the appended drawings. For the purpose of illustrating of the present subject matter, an example of construction of the present subject matter is provided as figures; however, the invention is not limited to the specific method and system disclosed in the document and the figures.
[008] The present subject matter 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.
[009] Figure 1 illustrates a glass manufacturing furnace system comprising a flow monitoring and control system for controlling a petcoke-air ratio in the glass manufacturing furnace system, in accordance with an embodiment of the present subject matter.
[010] Figure 2 illustrates the flow monitoring and control system for controlling a petcoke-air ratio in the glass manufacturing furnace system in accordance with an embodiment of the present subject matter.
[011] Figure 3 illustrates the flow monitoring and control system, in accordance with an embodiment of the present subject matter.
[012] Figure 4 illustrates a method for controlling a petcoke-air ratio in the glass manufacturing furnace system, 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 systems and methods for controlling a petcoke-air ratio in the 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, systems and methods for controlling a petcoke-air ratio in the glass manufacturing furnace system are now described. The disclosed embodiments for controlling a petcoke-air ratio in the 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 controlling a petcoke-air ratio in the glass manufacturing furnace system. However, one of ordinary skill in the art will readily recognize that the present disclosure for controlling a petcoke-air ratio in the glass manufacturing furnace system not intended to be limited to the embodiments described, but is to be accorded the widest scope consistent with the principles and features described herein.
[015] A typical composition of petroleum coke (petcoke) is given as follow: 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%. Further, the other comprises vanadium, and sodium. Monitoring and control of flow of a flow of fuel in the glass manufacturing is critical as the temperature/heat generated after combustion of the fuel directly affects the quality of fuel and the life of the furnace. In a glass manufacturing furnace system, the conventionally known flow monitoring and control system fail as the petcoke is a super fin particulate matter which is further mixed and suspended in air. Thus, conventional flow measuring devices are not able to measure the flow of such a petcoke air mixture, along with failing to monitor and control the flow of petcoke-air mixture.
[016] In implementation of the present subject matter, a flow monitoring and control system and method system for controlling a petcoke-air ratio in the glass manufacturing furnace system is disclosed. In the implementation, sensor data associated with one or more sensors located in a glass manufacturing furnace system is obtained. The sensor data comprises frequency, temperature data and amplitude data associated with a petcoke-air mixture flowing through the glass manufacturing furnace system. Upon obtaining the sensor data, a petcoke-air mixture flow rate, a petcoke-air ratio and a petcoke flow rate may be computed based on the sensor data. Further to computation, a petcoke-air mixture flow rate variance, a petcoke-air ratio variance and a petcoke flow rate variance may be generated. In one example, the petcoke-air mixture flow rate variance may be generated based on a comparison of the petcoke-air mixture flow rate with a predefined petcoke-air mixture flow rate, the petcoke-air ratio variance may be generated based on a comparison of the petcoke-air ratio with a predefined petcoke-air ratio, and the petcoke flow rate variance may be generated based on a comparison of the petcoke flow rate with a predefined petcoke flow rate. Finally after generation, a speed of a variable frequency drive motor coupled to a screw conveyers and roots blower may be altered based on the petcoke-air mixture flow rate variance, the petcoke-air ratio variance and the petcoke flow rate variance thereby controlling the petcoke-air ratio in the glass manufacturing furnace system.
[017] Figure 1 illustrates a glass manufacturing furnace system 100 comprising a control system 200 for controlling a petcoke-air ratio in the glass manufacturing furnace system 100, in accordance with an embodiment of the present subject matter, is disclosed. Further, table 1 below discloses the elements of the glass manufacturing furnace system 100.
Table 1: List of elements in figure 1
Reference No. Definition Reference No Definition
101 Big bag unloading machine 111 Manual slide gate
102, 104, 113 Rotary Air lock feeder 112 Screw conveyor with VDF
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 Petcoke burner
108, 117 Dust collector 122 Air Atomizing
109 Service silo 123 Furnace
110A, 110B Single shaft agitator 124 Chimney
125 Regenerator
[018] In one embodiment, the glass manufacturing furnace system 100 comprising a control system 200 is disclosed with reference to figure 1. In the embodiment, the pet coke may be received at the glass manufacturing furnace system 100 site in jumbo bags (not shown) for one example of 1 ton capacity. In one example, the j¬umbo 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 transferring petcoke towards the furnaces. The big bag unloading machine 101 may be 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 petcoke may be extracted, which may be fed to rotary screen 103 via rotary Air Lock feeder 102, of unloading machine. A rotary type screen 103 may be provided for screening the received pet coke to eliminate the foreign bodies and or impurities. The pneumatic screw hopper 105 may be provided to collect the screened petcoke. The pneumatic screw pump 106 may be used to convey the petcoke, pneumatically to service silo 109. A rotary air lock feeder 104 may be provided above the pneumatic screw pump to avoid any air leakage or back pressure and to ensure smooth petcoke flow. The pneumatic screw pump 106 conveys the petcoke. A twin lobe positive displacement roots blower 107 may be provided for air transportation. The conveyed petcoke may be 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 may be positioned near the furnace area. The service silo 109 may be provided with extraction system. The silo may be also provided with purging system, explosion flaps and bag filter. The single shaft agitator 110A &110B may be provided for smooth flow of petcoke. The screw conveyer or dosing screw 112 shall extract the petcoke from service silo 109 and feeds to pump hopper 114 via Rotary Air lock feeder 113. Further, the pump hopper 114 discharges the petcoke to pneumatic screw pump 115. A twin lobe positive displacement roots blower 116 may be used for conveying air to the pneumatic screw pump 115. The piping arrangement may be done to suit furnace requirement. The first pneumatic diverter or reversal system 120 and second pneumatic diverter or return line valve 118 conveys the petcoke to service silo 109. The burners 121A and 121B are designed to contain roots blower pressure air. Additional roots blower 122 may be configured which may provide air and also perform 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). Further, a control system 200 may be installed for controlling and monitoring the petcoke flow and ratio.
[020] Various modifications to glass manufacturing 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 manufacturing furnace system 100 may comprises other systems and machines and the like along with the control system 200.
[021] Figure 2 illustrates a control system 200 for the glass manufacturing furnace system 100 for controlling the petcoke flow and ratio in accordance with an embodiment of the present subject matter. In one embodiment, the control system 200 may comprise sensor 202, sensor cable 204, C-box 206, connection cable 208, evaluation unit 212, current cable 210, and electricity plug 214. The control system 200 may be further connected to the Screw conveyor with VFD 112. Further, the sensor data can be obtained from the flow sensors and furnace sensors. The flow sensors comprises of air flow sensor(s), flow sensor for petcoke, exhaust gas temperature gauge for the flue gas temperature data and furnace sensors comprises of temperature sensors for furnace.
[022] In the embodiment, data associated with one or more sensors 202 obtain the sensor data utilizing a microwave technology. The sensor data may comprises frequency, temperature data and amplitude data associated with the petcoke air mixture flowing through the glass manufacturing furnace system 100 which is further processed. Further, the obtained data is transferred to the flow monitoring and control system unit 212 via the C-box 206. Further, the flow monitoring and control system unit 212 may generate one or more instructions for altering a speed of a variable frequency drive motor coupled to a screw conveyers and roots blower 112 thereby controlling the petcoke-air ratio in the glass manufacturing furnace system. In the embodiment, in one embodiment the instruction signal from the flow monitoring and control system unit 212 via the signal cable 208 is transferred to the variable frequency drive (VFD) motor coupled to the screw conveyor 112 for increase/ decrease the flow of petcoke and petcoke ratio in accordance with the requirement of temperature in the furnace 123. Herein, the glass manufacture data comprises of molten glass data, batch data, operator data etc. and user may also give the input for firing up the petcoke in the glass manufacturing system as user data but within the predefined safety working range of the glass manufacturing furnace system i.e. predefined criterion. The system may further generate alarm signal if the potential load of the system exceeds or work below the predefined criterion of the glass manufacturing furnace system.
[023] In one example, sensor(s) 202 may be based on the microwave technology. The sensor(s) 202 may also be usable in metal ducts. In the said example, through the coupling of the microwave in the duct it is created a homogenous measured field. During operation, the microwave energy is reflected by the solid particles of petcoke flowing in the system and is received by the sensor 202. These signals are evaluated in frequency and amplitude. Because of the selective frequency evaluation, only moving particles are measured by the sensor 202.
[024] Various modifications to the control system 200 will be readily apparent to those skilled in the art based on the description and the generic principles herein may be applied to other embodiment. Furthermore, one of ordinary skill in the art will readily recognize the control system 200 may comprises may other systems and machines and the like.
[025] Referring now to Figure 3, the flow monitoring and control system 212, herein after referred to as system 212 is illustrated in accordance with an embodiment of the present subject matter. In one embodiment, the system 212 may include at least one processor 302, an input/output (I/O) interface 304, a data 310 and a memory 306. The at least one processor 302 may be implemented as one or more microprocessors, microcomputers, microcontrollers, digital signal processors, central processing units, state machines, logic circuitries, and/or any devices that manipulate signals based on operational instructions. Among other capabilities, the at least one processor 302 may be configured to fetch and execute computer-readable instructions stored in the memory 306.
[026] The I/O interface 304 may include a variety of software and hardware interfaces, for example, a web interface, a graphical user interface, and the like. The I/O interface 304 may allow the system 212 to interact with the user directly or through the client devices. Further, the I/O interface 304 may enable the system 212 to communicate with other computing devices, such as web servers and external data servers (not shown). The I/O interface 304 can facilitate multiple communications within a wide variety of networks and protocol types, including wired networks, for example, LAN, cable, etc., and wireless networks, such as WLAN, cellular, or satellite. The I/O interface 304 may include one or more ports for connecting a number of devices to one another or to another server.
[027] The memory 306 may include any computer-readable medium or computer program product known in the art including, for example, volatile memory, such as static random access memory (SRAM) and dynamic random access memory (DRAM), and/or non-volatile memory, such as read only memory (ROM), erasable programmable ROM, flash memories, hard disks, optical disks, and magnetic tapes. The memory 406 may include modules 308.
[028] The modules 308 include routines, programs, objects, components, data structures, etc., which perform particular tasks or implement particular abstract data types. In one implementation, the modules 308 may comprise an obtaining module 312, a monitoring module 314, a controlling module 316 and an other module 318. The other modules 318 may include programs or coded instructions that supplement applications and functions of the system 212. The modules 308 described herein may be implemented as software modules that may be executed in the cloud-based computing environment of the system 212.
[029] The memory 306, amongst other things, serves as a repository for storing data processed, received, and generated by one or more of the modules 308. The memory 306 may include data generated as a result of the execution of one or more modules in the other module 420. In one implementation, the memory may include data 310. Further, the data 310 may include a system data 422 for storing data processed, received, and generated by one or more of the modules 408. Furthermore, the data 410 may include other data 324 for storing data generated as a result of the execution of one or more modules in the other module 320.
[030] In one implementation, at first, a user may use I/O interface 304 to access the system 212. The user may register them using the I/O interface 304 in order to use the system 212. In one aspect, the user may access the I/O interface 304 of the system 302 for providing all predefined data or obtaining all output data.
OBTAINING MODULE 312
Referring to figure 3, in an embodiment the obtaining module 312 may obtain sensor data from one or more sensors located in a glass manufacturing furnace system. In one example, one sensor may be located at the inlet of a burner another sensor may be located along the pipes. In the example, the sensor may generate sensor data associated with the petcoke air mixture utilizing a microwave technology. Further, the sensor data may comprise frequency, temperature data and amplitude data associated with a petcoke-air mixture flowing through the glass manufacturing furnace system. In one example, the sensor data may also be related to flow of petcoke and petcoke air mixture at multiple locations across the petcoke glass manufacturing furnace system. Further, in one more example, the obtaining module 312 also may receive data on working parameters of the petcoke glass manufacturing furnace such as flow sensor data, furnace sensor data, glass manufacturing data which mainly comprises of petcoke flow rate, air flow rate, air combustion rate, flue gas generation rate, flue gas composition, furnace temperature, burner temperature, variable frequency drive motor speed, molten glass and like. In one example, at least one sensor may be located at the inlet of a burner configured to burn the petcoke-air mixture. Further, the sensor may generates sensor data associated with the petcoke air mixture entering the burner. The obtaining module 312 may store the data in system data 322.
MONITORING MODULE 314
[031] In the embodiment further to obtaining the sensor data from one or more sensors located across the glass manufacturing furnace system, the monitoring module 314 may compute a petcoke-air mixture flow rate, a petcoke-air ratio and a petcoke flow rate based on a the sensor data. Upon computing the monitoring module 314 may save the petcoke-air mixture flow rate, the petcoke-air ratio and the petcoke flow rate.
[032] In the embodiment, further to computing the petcoke-air mixture flow rate, the petcoke-air ratio and the petcoke flow rate, the monitoring module 314 may generate a petcoke-air mixture flow rate variance, a petcoke-air ratio variance and a petcoke flow rate variance. In one example, the petcoke-air mixture flow rate variance may be generated based on a comparison of the petcoke-air mixture flow rate with a predefined petcoke-air mixture flow rate, the petcoke-air ratio variance may be generated based on a comparison of the petcoke-air ratio with a predefined petcoke-air ratio. The petcoke flow rate variance may be generated based on a comparison of the petcoke flow rate with a predefined petcoke flow rate.
[033] Upon generating, the monitoring module 314 may save all the computed and generated data in the system data 2.
CONTROLLING MODULE 316
[034] In the embodiment, further, to monitoring, the controlling module 316 may generate one or more instructions. In one example, the controlling module 316 may generate instructions based on predefined control condition. In one example, the predefined control condition may be difference in the current flow of petcoke and ideal flow of petcoke is less that 5%. In one more example, the difference between the actual flow rate of petcoke i.e. 5 kg/min and the optimum flow rate of petcoke is 7.5 kg/min, the instruction may show the 50% increase in flow of petcoke depending on the working parameters of the glass manufacturing furnace system.
[035] In one embodiment, further, to monitoring, the controlling module 316 may alter a speed of a variable frequency drive motor coupled to a screw conveyer based on the petcoke-air mixture flow rate variance, the petcoke-air ratio variance and the petcoke flow rate variance thereby controlling the petcoke-air ratio in the glass manufacturing furnace system. Further, the speed of the variable frequency drive motor is altered between a maximum speed and a minimum speed of the variable frequency drive motor.
[036] In one embodiment, the controlling module 316 may initiate an alarm when one of the petcoke-air mixture flow rate, the petcoke-air ratio, the petcoke flow rate, the petcoke-air mixture flow rate variance, the petcoke-air ratio variance and the petcoke flow rate variance exceeds a predefined a predefined maximum threshold or decreases below a predefined minimum threshold, and wherein the alarm is one or more of a message to the administrator, a siren, or a flashing light.
[037] In one implementation, the alarm may be based on the flow sensor data obtained for the optimum rate of flow of petcoke in the glass furnace manufacturing system. the controlling module 316 may initiate the alarm signal if the operating conditions of the glass manufacturing system fall outside the predefined safety working range of the glass manufacturing system.
[038] In one embodiment, various automatics control valves located at multiple locations in the petcoke filed glass furnace may also be altered. The automatic control valves may regulate the flow of petcoke to achieve ideal or optimal quantity of petcoke.
[039] In one embodiment, the controlling module 316 may provide an alteration instruction to the user, wherein the user may manually operate one or more values or the variable frequency drive motor to thereby controlling a petcoke-air ratio in the glass manufacturing furnace system.
[040] In one embodiment, the controlling module 316 may display the petcoke-air mixture flow rate, the petcoke-air ratio, the petcoke flow rate, the petcoke-air mixture flow rate variance, the petcoke-air ratio variance, the petcoke flow rate variance and the speed of the variable frequency drive motor to one or more users.
[041] In one embodiment, the controlling module 316 may provide real time data analytics and trends to the user on the status of petcoke, petcoke-air ratio and other parameters in the petcoke glass manufacturing furnace system.
[042] Exemplary embodiments discussed above may provide certain advantages. Though not required to practice aspects of the disclosure, these advantages may include those provided by the following features.
[043] Some embodiments enable the system and the method to optimize the furnace temperature, burner temperature depending on the molten glass data, batch size, shift size and the like.
[044] Some embodiments enable the system and the method to achieve complete combustion.
[045] Some embodiments enable the system and the method manufacture good quality glass.
[046] Some embodiments enable the system and the methods to reduce flue gases.
[047] Some embodiments enable the system and the method to reduce operation cost.
[048] Some embodiments enable the system and the method enable precise to control the petcoke air ratio and hence maintain better parameter control of glass furnace
[049] Some embodiments enable the system and the method enable increasing quantity of petcoke and while simultaneously keeping the air and petcoke ratio constant
[050] Referring now to Figure 4, a method 400 for controlling a petcoke-air ratio in a glass manufacturing furnace system is shown, in accordance with an embodiment of the present subject matter. The method 400 may be described in the general context of computer executable instructions. Generally, computer executable instructions can include routines, programs, objects, components, data structures, procedures, modules, functions, etc., that perform particular functions or implement particular abstract data types.
[051] The order in which the method 400 for controlling a petcoke-air ratio in a glass manufacturing furnace system 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 400 or alternate methods. Additionally, individual blocks may be deleted from the method 400 without departing from the spirit and scope of the subject matter described herein. Furthermore, the method can be implemented in any suitable hardware, software, firmware, or combination thereof. However, for ease of explanation, in the embodiments described below, the method 400 for controlling a petcoke-air ratio in a glass manufacturing furnace system may be considered to be implemented in the above described system 212.
[052] At block 402, sensor data associated with one or more sensors located in a glass manufacturing furnace system may be obtained. The sensor data may comprise frequency data and amplitude data associated with a petcoke-air mixture flowing through the glass manufacturing furnace system. In the implementation, the obtaining module 312 may obtain sensor data associated with one or more sensors and store the sensor data in the system data 322.
[053] At block 404, a petcoke-air mixture flow rate, a petcoke-air ratio and a petcoke flow rate may be computed based on the sensor data. In on implementation the monitoring module 314 may compute a petcoke-air mixture flow rate, a petcoke-air ratio and a petcoke flow rate. Further, monitoring module 314 may store the petcoke-air mixture flow rate, the petcoke-air ratio and the petcoke flow rate in the system data 322.
[054] At block 406, a petcoke-air mixture flow rate variance, a petcoke-air ratio variance and a petcoke flow rate variance may be generated. The petcoke-air mixture flow rate variance may be generated based on a comparison of the petcoke-air mixture flow rate with a predefined petcoke-air mixture flow rate, the petcoke-air ratio variance may be generated based on a comparison of the petcoke-air ratio with a predefined petcoke-air ratio, and the petcoke flow rate variance may be generated based on a comparison of the petcoke flow rate with a predefined petcoke flow rate. In on implementation, the monitoring module 314 may generate a petcoke-air mixture flow rate variance, a petcoke-air ratio variance and a petcoke flow rate variance. Further the monitoring module 314 may store the petcoke-air mixture flow rate variance, the petcoke-air ratio variance and the petcoke flow rate variance in the system data 322.
[055] At block 408, a speed of a variable frequency drive motor coupled to a screw conveyers and roots blower may be altered based on the petcoke-air mixture flow rate variance, the petcoke-air ratio variance and the petcoke flow rate variance thereby controlling the petcoke-air ratio in the glass manufacturing furnace system. In on implementation the controlling module 316 may alter a speed of a variable frequency drive motor coupled to a screw conveyer. Further the controlling module 316 may store the magnitude of alternation and the new speed of variable frequency drive motor in the system data 322.
[056] Exemplary embodiments discussed above may provide certain advantages. Though not required to practice aspects of the disclosure, these advantages may include a method and a flow monitoring and control system for controlling a petcoke-air ratio in a glass manufacturing furnace system.
[057] Although implementations of the flow monitoring and control system and the methods for controlling a petcoke-air ratio 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 and methods are disclosed as examples of implementations for controlling a petcoke-air ratio in a glass manufacturing furnace system.
,CLAIMS:
1. A method for controlling a petcoke-air ratio in a glass manufacturing furnace system, the method comprising:
obtaining, by a processor, sensor data associated with one or more sensors located in a glass manufacturing furnace system, wherein the sensor data comprises frequency, temperature data and amplitude data associated with a petcoke-air mixture flowing through the glass manufacturing furnace system;
computing, by the processor, a petcoke-air mixture flow rate, a petcoke-air ratio and a petcoke flow rate based on a the sensor data;
generating, by the processor, a petcoke-air mixture flow rate variance, a petcoke-air ratio variance and a petcoke flow rate variance, wherein the petcoke-air mixture flow rate variance is generated based on a comparison of the petcoke-air mixture flow rate with a predefined petcoke-air mixture flow rate, wherein the petcoke-air ratio variance is generated based on a comparison of the petcoke-air ratio with a predefined petcoke-air ratio, and wherein the petcoke flow rate variance is generated based on a comparison of the petcoke flow rate with a predefined petcoke flow rate; and
altering, by the processor, a speed of a variable frequency drive motor coupled to a screw conveyers and roots blower based on the petcoke-air mixture flow rate variance, the petcoke-air ratio variance and the petcoke flow rate variance thereby controlling the petcoke-air ratio in the glass manufacturing furnace system.

2. The method of claim 1, wherein at least one sensor of the one or more sensors is located at the inlet of a burner configured to burn the petcoke-air mixture, wherein the sensor generates sensor data associated with the petcoke air mixture entering the burner.

3. The method of claim 1, further comprising displaying the petcoke-air mixture flow rate, the petcoke-air ratio, the petcoke flow rate, the petcoke-air mixture flow rate variance, the petcoke-air ratio variance, the petcoke flow rate variance and the speed of the variable frequency drive motor.

4. The method of claim 1, further comprising initiating and alarm when one of the petcoke-air mixture flow rate, the petcoke-air ratio, the petcoke flow rate, the petcoke-air mixture flow rate variance, the petcoke-air ratio variance and the petcoke flow rate variance exceeds a predefined a predefined maximum threshold or decreases below a predefined minimum threshold, and wherein the alarm is one or more of a message to the administrator, a siren, or a flashing light.

5. The method of claim 1, wherein the speed of the variable frequency drive motor is altered between a maximum speed and a minimum speed of the variable frequency drive motor.

6. A flow monitoring and control system for controlling a petcoke-air ratio in a glass manufacturing furnace system, the flow monitoring and control system comprising:
a memory;
a processor coupled to the memory, wherein the processor is capable of executing instructions to perform steps of:
obtaining sensor data associated with one or more sensors located in a glass manufacturing furnace system, wherein the sensor data comprises frequency data and amplitude data associated with a petcoke-air mixture flowing through the glass manufacturing furnace system;
computing a petcoke-air mixture flow rate, a petcoke-air ratio and a petcoke flow rate based on the sensor data;
generating a petcoke-air mixture flow rate variance, a petcoke-air ratio variance and a petcoke flow rate variance, wherein the petcoke-air mixture flow rate variance is generated based on a comparison of the petcoke-air mixture flow rate with a predefined petcoke-air mixture flow rate, wherein the petcoke-air ratio variance is generated based on a comparison of the petcoke-air ratio with a predefined petcoke-air ratio, and wherein the petcoke flow rate variance is generated based on a comparison of the petcoke flow rate with a predefined petcoke flow rate; and
altering a speed of a variable frequency drive motor coupled to a screw conveyers and roots blower based on the petcoke-air mixture flow rate variance, the petcoke-air ratio variance and the petcoke flow rate variance thereby controlling the petcoke-air ratio in the glass manufacturing furnace system.

7. The flow monitoring and control system of claim 6, wherein at least one sensor of the one or more sensors is located at the inlet of a burner configured to burn the petcoke-air mixture, wherein the sensor generates sensor data associated with the petcoke air mixture entering the burner.

8. The flow monitoring and control system of claim 6, further comprising displaying the petcoke-air mixture flow rate, the petcoke-air ratio, the petcoke flow rate, the petcoke-air mixture flow rate variance, the petcoke-air ratio variance, the petcoke flow rate variance and the speed of the variable frequency drive motor.

9. The flow monitoring and control system of claim 6, further comprising initiating and alarm when one of the petcoke-air mixture flow rate, the petcoke-air ratio, the petcoke flow rate, the petcoke-air mixture flow rate variance, the petcoke-air ratio variance and the petcoke flow rate variance exceeds a predefined a predefined maximum threshold or decreases below a predefined minimum threshold, and wherein the alarm is one or more of a message to the administrator, a siren, or a flashing light.

10. The flow monitoring and control system of claim 6, wherein the speed of the variable frequency drive motor is altered between a maximum speed and a minimum speed of the variable frequency drive motor.