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:
PETROLEUM COKE AND AIR MIXING SYSTEM

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 it is to be performed.

CROSS-REFERENCE TO RELATED APPLICATIONS AND PRIORITY
[001] The present application claim priority from provisional patent application having application number 5008/CHE/2015 filed on September 18, 2015.
TECHNICAL FIELD
[002] The present subject matter described herein, in general, relates to a petroleum coke (petcoke) fired glass manufacturing furnace system and in particular to a petroleum coke and air mixing system for a petroleum coke fired glass manufacturing furnace system
BACKGROUND
[003] 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. It 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.
[004] 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.
[005] However, the continuing upward spirals of energy costs, for example natural gas, have forced use of petroleum coke in manufacturing of glass. Typically, petroleum coke is in a super fine powdered form and transportation of petroleum coke from storage to the burner is difficult. Further, the petroleum coke requires substantial amount of air for combustion. Conventional methods of petroleum coke and air mixing utilized numerous complicated systems and steps, thus resulting in increased cost and effort.

SUMMARY
[006] Before the present system for a petroleum coke and air mixing for a petroleum coke fired 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 disclosure. 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 petroleum coke and air mixing system for a petroleum coke fired 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.
[007] In one implementation, a petroleum coke and air mixing system for a glass manufacturing furnace system may be disclosed. In one embodiment, the petroleum coke and air mixing system may comprise a service silo (109). During operation the service silo (109) maybe configured to receive a petroleum coke wherein the petroleum coke is in a powder form. The petroleum coke and air mixing system may further comprise a screw conveyer (112), connected to the service silo (109) via single shaft agitator (110A, 110B). The screw conveyor (112) maybe configured to extract the petroleum coke from the service silo (109). The petroleum coke and air mixing system may further comprise a pump hopper (114) connected to the screw conveyor (112) via rotary air lock feeder (113). The pump hopper (114) maybe configured to receive the petroleum coke from the screw conveyor (112). The petroleum coke and air mixing system may further comprise a pneumatic screw pump (115) connected to the pump hopper (114) at one end and a twin lobe positive displacement roots blower (116) at other end. The pneumatic screw pump (115) maybe configured to receive the petroleum coke from the pump hopper (115) and air from the twin lobe positive displacement roots blower (116). The pneumatic screw pump (115) maybe configured to mix the petroleum coke and air, thereby enabling petroleum coke and air mixing for a glass manufacturing furnace system (100).

BRIEF DESCRIPTION OF THE DRAWINGS
[008] The foregoing detailed description of embodiments of a petroleum coke and air mixing system for a petroleum coke fired glass manufacturing furnace system is better understood when read in conjunction with the appended drawings. For the purpose of illustration of the present subject matter, an example of construction of a petroleum coke and air mixing system for a petroleum coke fired 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.
[009] In the detailed description, an embodiment of the petroleum coke and air mixing system for a petroleum coke fired 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.
[010] Figure 1 illustrates a petroleum coke fired glass manufacturing furnace, in accordance with an embodiment of the present subject matter.
[011] Figure 2 illustrates a petroleum coke and air mixing system for a petroleum coke fired glass manufacturing furnace system in accordance with an embodiment of the present subject matter.
DETAILED DESCRIPTION
[012] 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 petroleum coke and air mixing system for a petroleum coke fired 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, a petroleum coke and air mixing system for a petroleum coke fired glass manufacturing furnace system are now described. The disclosed embodiments for a petroleum coke and air mixing system for a petroleum coke fired glass manufacturing furnace system are merely examples of the disclosure, which may be embodied in various forms.
[013] A typical composition of petroleum coke 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 others comprise of vanadium, and sodium. Monitoring, control, mixing of petroleum coke and air in the glass manufacturing is critical as the temperature/ heat generated after combustion of the fuel directly affects the quality of fuel.
[014] In a petroleum coke fired glass manufacturing furnace system, the conventionally know glass manufacturing furnace system fail as the petroleum coke is typically a super fine particulate matter and transportation of petroleum coke from storage to the burner is difficult. Further, the petroleum coke requires substantial amount of air for combustion. Conventional methods of petroleum coke air mixing system utilize numerous complicated systems and steps, thus resulting in increased cost and effort.
[015] In implementation of the present subject matter, a petroleum coke and air mixing system for a petroleum coke fired glass manufacturing furnace system, is disclosed. In the implementation, a petroleum coke and air mixing system comprises a service silo to receive a powdered petroleum coke. The service silo is further connected in to the single shaft agitator, screw conveyer, pump hopper, pneumatic screw pump, rotary air lock feeder and twin lobe positive displacement roots blower. The petroleum coke and air mixing system further comprises of solid flow meter to measure flow of the petroleum coke in the glass manufacturing furnace system. Further, the petroleum coke air mixture control system is connected electronically to the screw conveyor, the pneumatic screw pump and the twin lobe positive displacement roots blower to control flow of the petroleum coke in the glass manufacturing furnace system. The use of pneumatic screw pump with the roots blower at low air pressure enables uniform mixing of petroleum coke and air without requiring a separate mixing chamber. The petroleum coke air mixture control system enables real time control on the mixing of the petroleum coke and the air.
[016] 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 a petroleum coke and air mixing system for a petroleum coke fired glass manufacturing furnace system. However, one of ordinary skill in the art will readily recognize that the present disclosure of a petroleum coke and air mixing system for a petroleum coke fired 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 principles and features described herein.
[017] Referring now to Figure 1, where the figure 1 illustrates a petroleum coke fired glass manufacturing furnace system (100), in accordance with an embodiment of the present subject matter, is disclosed. Further, Table 1 below, disclose some of the illustrative elements of glass manufacturing furnace system (100).
[018] In implementation of the present subject matter, a petroleum coke flow monitoring and control system for a petroleum coke fired glass manufacturing furnace is disclosed. Figure 1 illustrates a petroleum coke fired glass manufacturing furnace (100), in accordance with an embodiment of the present subject matter, is disclosed. Further, Table 1 below, disclosed the elements of the glass manufacturing 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 VDF
103 Rotary screen 118 Return line with valve
105, 114 Pneumatic Screw hopper 119a, 119b Pneumatic Valve
106, Pneumatic screw pump 120 Reversal system
107, 116 Roots blower 121A, 121B Petroleum coke burner
108, 117 Dust collector 122 Air Atomizing
109 Service silo 123 Furnace
110A, 110B Single shaft agitator 124 Chimney
115 Pneumatic screw pump assembly 125 Regenerator

[019] In the embodiment the glass manufacturing furnace system (100) is as follows. The pet coke is received at the glass manufacturing 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 maybe 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) provided for transportation of air. 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).
[020] 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 or dosing screw (112) shall extract the material from service silo (109) and feed 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 burners and Pneumatic Valves (119a) & (119b). The burners are specially designed for low pressure air (0.4 to 0.6 Kg/cm2) to the 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 roots blower (122) is considered for burners which will provide the swirl air and also performs the function of cooling the burner and retaining the flame. Further the furnace (1230 may be connected to a chimney (124) via a flue gas system (not shown).
[021] 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 comprise other systems and machines and the like.
[022] Figure 2 illustrates a petroleum coke and air mixing system (200) for mixing of petroleum coke in the petroleum coke fired glass melting furnace (100), in accordance with an embodiment of the present subject matter. In one embodiment of the petroleum coke and air mixing system (200), Service silo (109) is positioned such as to receive petroleum coke in powdered form. Further, a single shaft agitator (110A) & (110B) is provided at the service silo (109) for smooth flow of petroleum coke. Connected to the single shaft agitator (110A) & (110B) is the screw conveyer (112) that extracts the petroleum coke from service silo (109) and feeds to the pump hopper (114) via Rotary Air lock feeder (113). Further, the pump hopper (114) discharges the petroleum coke to the pneumatic screw pump (115) for pneumatic conveying of petroleum coke. Connected to the pneumatic screw pump (115) is a twin lobe positive displacement roots blower (116) used for conveying air to the pneumatic screw pump (115). In one implementation, the low pressure air from the roots blower (107) is mixed with petroleum coke at pressure of 0.4 to 0.6 bar. The use of pneumatic screw pump (115) with the roots blower (107) at low pressure air enables uniform mixing of petroleum coke and air without requiring a separate mixing chamber. In the embodiment the mixing of the petroleum coke and the air is in the pneumatic screw pump (115). Further the mixed petroleum coke and air are transported to the burner.
[023] In one embodiment, the petroleum coke and air mixing system (200) comprises the pet coke air mixture control system (control box) (212) and a solid flow meter (202). In one embodiment, the solid flow metre (202), measures the flow of petroleum coke in the petroleum coke fired glass manufacturing furnace system furnace (100). The petroleum coke air mixture control system (212) is electronically connected to screw conveyer (112), pneumatic screw pump (115) and twin lobe positive displacement roots blower (116) for controlling the mixing of the petroleum coke and air. During operation the petroleum coke air mixture control system (212) enables real time control on the mixing of petroleum coke and air. In one example, the petroleum coke air mixture control system (212) may obtain real time information on the quantity of a petroleum coke-air mixture ratio in the glass manufacturing furnace system (100). In another example, the petroleum coke air mixture control system (212) may obtain real time information on the quality of the petroleum coke-air mixture ratio in the glass manufacturing furnace system (100). The petroleum coke-air mixture ratio is the ratio of the amount of petroleum coke and air in the petroleum coke-air mixture. Further, in another example, the petroleum coke air mixture control system (212) may obtain real time information on the composition of the petroleum coke and the air, quantity of flue gases generated in the glass manufacturing furnace system (100), speed of pneumatic screw pump (115), temperature of glass manufacturing furnace system (100) and the rate of flow of air from the twin lobe positive displacement roots blower (116). In one example, the real time information may be obtained by sensors and measuring devices, known in the art, located at one or more location across the petroleum coke fired glass melting furnace (100).
[024] In one embodiment, petroleum coke air mixture control system (212) may compute the change in rate of flow of petroleum coke and the air. In one example, the computation of change in rate of flow of the petroleum coke and the air is based upon the optimal rate of flow of the petroleum coke and the air and an actual rate of flow of the petroleum coke and the air in the air glass manufacturing furnace system (100). The rate of flow of the petroleum coke and the air is based on the real time information. In one embodiment, the petroleum coke air mixture control system (212) may further actuate the automatic control valve to control the flow of petroleum coke and air for effective mixing.
[025] In one other embodiment, the petroleum coke air mixture control system (212) may control the flow of the petroleum coke and the air based on the optimal rate of flow of petroleum coke and the air and the actual rate of flow of the petroleum coke and the air in the glass manufacturing furnace system (100). In one example, the flow of petroleum coke is controlled is based on the variation in the speed of the screw conveyor (112), single shaft agitator (110A, 110B), rotary air lock feeder (113), pump hopper (114) and the pneumatic screw pump (115). In another example, the flow of the air is controlled based on the variation in the speed of the twin lobe positive displacement roots blower (116). For optimal mixing of the petroleum coke and the air, the speed of all the elements of the glass manufacturing furnace system (100) maybe increased or decreased.
[026] In another embodiment, the dust collector (108, 117) enables removal of pressure from the equipment and pipe-lines for uninterrupted flow of the petroleum coke mixed with air and other chemicals.
[027] Various modifications to the pet coke air mixture 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 embodiments. Furthermore, one of ordinary skill in the art will readily recognize that the petroleum coke air mixture system (200) may comprise many other systems and machines and the like.
[028] 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 a petroleum coke and air mixing system for a petroleum coke fired glass manufacturing furnace system.
[029] Some embodiments of the petroleum coke and air mixing system for a petroleum coke fired glass manufacturing furnace system enable effective mixing of petroleum coke with the air.
[030] Some embodiments of the petroleum coke and air mixing system for a petroleum coke fired glass manufacturing furnace system enable controlled and effective mixing of petroleum coke with the air.
[031] Although implementations for a petroleum coke and air mixing system for a petroleum coke fired 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 for a petroleum coke and air mixing system for a petroleum coke fired glass manufacturing furnace system. However, one of ordinary skill in the art will readily recognize that the present disclosure is 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.
,CLAIMS:WE CLAIM:
1. A petroleum coke and air mixing system (200) for a glass manufacturing furnace system (100), the petroleum coke and air mixing system comprising:
a service silo (109), wherein the service silo (109) is configured to receive a petroleum coke, wherein the petroleum coke is in a powder form;
a screw conveyer (112), connected to the service silo (109) via single shaft agitator (110A, 110B), wherein the screw conveyor (112) is configured to extract the petroleum coke from the service silo (109);
a pump hopper (114) connected to the screw conveyor (112) via rotary air lock feeder (113), wherein the pump hopper (114) is configured to receive the petroleum coke from the screw conveyor (112);
a pneumatic screw pump (115) connected to the pump hopper (114) at one end and a twin lobe positive displacement roots blower (116) at other end; wherein the pneumatic screw pump (115) is configured to receive the petroleum coke from the pump hopper (115) and air from the twin lobe positive displacement roots blower (116), wherein the pneumatic screw pump (115) is configured to mix the petroleum coke and air, thereby enabling petroleum coke and air mixing for a glass manufacturing furnace system (100).

2. The petroleum coke and air mixing system (200) as claimed in claim 1, wherein the petroleum coke and air mixing system further comprises a single shaft agitator (110A, 110B) connected to the service silo (109), wherein the single shaft agitator (110A, 110B) is configured to provide smooth flow of the petroleum coke;

3. The petroleum coke and air mixing system (200) as claimed in claim 1, wherein the petroleum coke and air mixing system further comprises a solid flow meter (202), wherein the solid flow meter (202) measures flow of the petroleum coke in the glass manufacturing furnace system (100).

4. The petroleum coke and air mixing system (200) as claimed in claim 1, wherein the twin lobe positive displacement roots blower (116) further comprises providing air at low pressure in the range of 0.4 to 0.6 bar.

5. The petroleum coke and air mixing system (200) as claimed in claim 1, wherein the petroleum coke and air mixing system (200) further comprises a petroleum coke air mixture control system (212), wherein the petroleum coke air mixture control system (212) is connected electronically to the screw conveyor (112), the pneumatic screw pump (115), and the twin lobe positive displacement roots blower (116), wherein the petroleum coke air mixture control system (212) is configured to:
obtain a real time information, wherein the real time information comprises one or more of quantity of a petroleum coke-air mixture ratio in the glass manufacturing furnace system (100), quality of the petroleum coke-air mixture ratio in the glass manufacturing furnace system (100), the composition of the petroleum coke and the air, quantity of flue gases generated in the glass manufacturing furnace system, speed of pneumatic screw pump (115), temperature of glass manufacturing furnace system (100) and the rate of flow of air from the twin lobe positive displacement roots blower (116);
compute an optimal rate of flow of the petroleum coke and the air and an actual rate of flow of the petroleum coke and the air in the air glass manufacturing furnace system (100) based on the real time information; and
control the flow of the petroleum coke and the air based on the optimal rate of flow of petroleum coke and the air and the actual rate of flow of the petroleum coke and the air in the glass manufacturing furnace system (100).

6. The petroleum coke and air mixing system (200) as claimed in claim 5, wherein the flow of the petroleum coke is controlled based on the variation in the speed of the screw conveyor (112), single shaft agitator (110A, 110B), rotary air lock feeder (113), pump hopper (114) and the pneumatic screw pump (115).

7. The petroleum coke and air mixing system (200) as claimed in claim 5, wherein the flow of the air is controlled based on the variation in the speed of the twin lobe positive displacement roots blower (116).