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 DOSING 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 in which 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 4232/CHE/2015 filed on August 14, 2015.
TECHNICAL FIELD
[002] The present subject matter described herein, in general, relates to petroleum coke fired glass melting furnace system and in particular to a petroleum coke dosing system for dosing of petroleum coke, with one or more chemical, in a glass manufacturing furnace system.
BACKGROUND
[003] Petroleum coke (pet coke) is a black-coloured solid composed primarily of carbon, and may contain sulfur, metals, and non-volatile inorganic compounds. A typical composition of petroleum coke (pet 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 other comprises vanadium, and sodium. 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 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 petroleum coke.
[004] 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 and furnace oil, have forced use of petroleum coke in manufacturing of glass. Due to the high sulfur content and the presence of vanadium, sodium, petroleum coke is not commonly used as a fuel in the glass industry.
[005] Typically, additives are mixed in the petroleum coke to overcome the side effects of petroleum coke in the glass manufacturing process. But the conventional methods for dosing lack control and agility. Further, conventional dosing process comprises mixing the pet coke and the chemical in a single hopper, thus rendering such mixing uneven. Further, the mixing of air with such a mixture is not uniform, resulting in uneven combustion and also affecting the glass quality being manufactured.
SUMMARY
[006] Before the present a petroleum coke dosing system for 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 a petroleum coke dosing system 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.
[007] In one implementation, a petroleum coke dosing system for dosing of petroleum coke, with one or more chemical, in a glass manufacturing furnace system, may be disclosed. In one embodiment, the petroleum coke dosing system may comprise a dosing hopper. The dosing hopper, during operation, may be configured to receive the one or more chemicals for dosing of petroleum coke. The petroleum coke dosing system may further comprise one or more control valve connected to the dosing hoper. During operation, the one or more control vale may be configured to control the flow of the chemical based on one or more of a rate of flow of chemical, a total percentage of vanadium in the petroleum coke, a total percentage of Sulphur in the petroleum coke, rate of flow of petroleum coke. The petroleum coke dosing system may furthermore comprise a conveyor connected to the control valve. During operation, the conveyor may be configured to receive a flow of chemical and convey the chemical for mixing, and the speed of conveyer may be based on a rate of flow of the petroleum coke in the glass manufacturing furnace system. The petroleum coke dosing system may also comprise a mixing chamber connected to the conveyer and a blower. During operation, the mixing chamber may be configured to receive the chemical for the conveyor and mix the chemicals with air. Further, the air may be supplied by the blower. The petroleum coke dosing system moreover comprises a pneumatic screw pump assembly connected to the mixing chamber via a pneumatic screw pump hopper. Further, during operation the pneumatic screw pump assembly may be configured to receive a petroleum coke-air mixture from the mixing chamber and mix the petroleum coke-air mixture with the chemical-air mixture, thereby dosing the petroleum coke, with one or more chemical, in a glass manufacturing furnace system.
BRIEF DESCRIPTION OF THE DRAWINGS
[008] The foregoing detailed description of embodiments of a petroleum coke dosing system for dosing of 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 construction of a petroleum coke dosing system for dosing of 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.
[009] In the detailed description, an embodiment of the petroleum coke dosing system for dosing of 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.
[010] Figure 1 illustrates a petroleum coke fired glass manufacturing furnace system, in accordance with an embodiment of the present subject matter.
[011] Figure 2 illustrates a petroleum coke dosing system for dosing of petroleum coke, with one or more chemical, in the 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 a petroleum coke dosing system for dosing of petroleum coke, with one or more chemical, 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, a petroleum coke dosing system for dosing of petroleum coke, with one or more chemical, in the glass manufacturing furnace system are now described. The disclosed embodiments a petroleum coke dosing system for dosing of petroleum coke, with one or more chemical, in the glass manufacturing furnace system are merely examples of the disclosure, which may be embodied in various forms.
[013] In implementation of the present subject matter, a petroleum coke dosing system for dosing of petroleum coke, with one or more chemical, in the glass manufacturing furnace system, is disclosed. In the implementation, a petroleum coke dosing system comprises a dosing hopper, one or more control valve connected to the dosing hoper, a conveyor connected to the control valve, a mixing chamber connected to the conveyer, and a pneumatic screw pump assembly connected to the mixing chamber via a pneumatic screw pump hopper, for enabling dosing of petroleum coke.
[014] In the implementation during operation, the dosing hopper may be configured to receive the one or more chemicals for dosing of petroleum coke and provide the one or more chemicals to the control valve. Further, the control valve may be configured to control the flow of the chemical based on one or more of a rate of flow of chemical, a total percentage of vanadium in the petroleum coke, a total percentage of Sulphur in the petroleum coke, rate of flow of petroleum coke. Further to controlling, the conveyor may be configured to receive a flow of chemical and convey the chemical for mixing. In one example, the speed of conveyer may be based on a rate of flow of the petroleum coke in the glass manufacturing furnace system. Upon conveying, the mixing chamber may be configured to receive the chemical for the conveyor and mix the chemicals with air. Further, the air may be supplied by a blower connected to the mixing chamber. Subsequent to mixing, the pneumatic screw pump assembly may be configured to receive a petroleum coke-air mixture from the mixing chamber and mix the petroleum coke-air mixture with the chemical-air mixture, thereby dosing the petroleum coke, with one or more chemical, in a glass manufacturing furnace system.
[015] 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 dosing system for dosing of petroleum coke, with one or more chemical, in the glass manufacturing furnace system. However, one of ordinary skill in the art will readily recognize that the present disclosure of a petroleum coke dosing system for dosing of petroleum coke, with one or more chemical, in the 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.
[016] Referring now to Figure 1, where the figure 1 illustrates a petroleum coke (pet coke) fired glass manufacturing furnace system 100, in accordance with an embodiment of the present subject matter, is disclosed. Further, table 1 below, disclosed some of the illustrative elements of 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
[017] In the embodiment during operation 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 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.
[018] 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 feeds to pump hopper 114 via Rotary Air lock feeder 113. Further, the pump hopper 114 discharges the petroleum coke to pneumatic screw pump assembly 115. A twin lobe positive displacement roots blower 116 is used for conveying air to the pneumatic screw pump assembly 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 burner 119a &119b. The burners are specially designed for high pressure air 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 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).
[019] 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 comprises other systems and machines and the like.
[020] In the embodiment, during operation, a petroleum coke bag in unloaded in the big bag unloading machine 101. Further, the petroleum coke is transferred to the service silo 109 by the dosing chamber 106. From the service silo 109 the petroleum coke is further transferred to the pump hopper 114. In one example, the petroleum coke is dosed with one or more chemicals for neutralization of vanadium. In the example, petroleum coke is dosed with Silica, Calcium, Magnesium and Aluminum, thus neutralizing the effect of vanadium and saving refractory in the furnace. From the pump hopper 114 the petroleum coke is further transferred to the pneumatic screw pump assembly 115. In one example, during the flow of petroleum coke in the pneumatic screw pump assembly 115, the petroleum coke is dosed with Calcium hydroxide [Ca (OH) 2] by a dosing system. In one other example, during the flow of petroleum coke in the pneumatic screw pump assembly 115, the petroleum coke is dosed with one or more chemicals Calcium hydroxide [Ca (OH) 2], Silica, Calcium, Magnesium and Aluminum.
[021] Figure 2 illustrates a petroleum coke (pet coke) dosing systems 200 comprising a first petroleum coke dosing system 200a and a second petroleum coke dosing system 200b for dosing of petroleum coke in the petroleum coke fired glass melting furnace 100. In one other embodiment, Table 2 below disclosed the illustrative elements of the petroleum coke dosing system 200.
Table 2: Elements of dosing system 200
Element Number Definition Element Number Definition
201a, 201b Electric hoist 205a, 205b Rotary air lock feeder
202a, 202b Dosing hopper 206a, 206b Screw conveyor with VFD motor
203a, 203b Manual control valve 207a, 207b Blower
204a, 204b Automatic control valve 208a, 208b Mixing chamber

[022] In the other embodiment the petroleum coke dosing system 200 comprise the first petroleum coke dosing system 200a and the second petroleum coke dosing system 200b. In one example, the first petroleum coke dosing system 200a is associated with a 1st chemical such as calcium hydroxide. In the example, the second petroleum coke dosing system 200b is 2nd chemical, such as a combination of aluminium and magnesium.
[023] The first petroleum coke dosing system 200a further comprises electric hoist201a, dosing hopper 202a, manual control valve 203a, automatic control valve 204a, rotary air lock feeder 205a, screw conveyor with VFD motor 206a, blower207a and mixing chamber 208a. Similarly the second petroleum coke dosing system 200b comprises electric hoist 201b, dosing hopper 202b, manual control valve 203b, automatic control valve 204b, rotary air lock feeder 205b, screw conveyor with VFD motor 206b, blower 207b and mixing chamber 208b.
[024] In the said embodiment, the dosage hopper 202a is connected to the pneumatic screw pump assembly 115 via the manual control valve 203a, automatic control valve 204a, rotary air lock feeder 205a, screw conveyor with VFD motor 206a and mixing chamber 208a. Further, the blower 207a is connected to mixing chamber 208a. Similarly the dosage hopper 202b is connected to the pneumatic screw pump assembly 115 via the manual control valve 203b, automatic control valve 204b, rotary air lock feeder 205b, screw conveyor with VFD motor 206b and mixing chamber 208b. Further, the blower 207b is connected to mixing chamber 208b. Further, the dosage chemicals are mixed with petroleum coke in pneumatic screw pump assembly 115.
[025] During operation, the chemicals of the dosing hoppers 202a, and 202b is mixed with the petroleum coke in pneumatic screw pump assembly 115. In one example, the amount of chemical flowing from the dosing hoppers 202a, and 202b and mixing with the petroleum coke controlled based on one or more of rate of flow of petroleum coke in the system, rate of flow of chemical, the amount of flue gas generated, amount of sulphur generated, amount of vanadium in petroleum coke, flow of air, rate of combustion, and the like. In one other example, the flow rate of chemical may be controlled in real time based on one or more control parameters.
[026] Various modifications to the petroleum coke dosing systems200a & 200b 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 the petroleum coke dosing systems200a & 200b.
[027] In one more embodiment, petroleum coke dosing system 200 for dosing of petroleum coke, with one or more chemical, in a glass manufacturing furnace system 100, may be disclosed. In the embodiment, the petroleum coke dosing system 200 comprises an electrical hoist 201 and a dosing hopper 201. In one example, during operation, the electrical hoist 201 may be configured to hoist one or more bags of petroleum coke and pour the bags comprising one or more chemicals in the dosing hopper 202 for dosing of petroleum coke. In one example, the dosing hopper 201is connected to a cleaning system (not shown) for cleaning the one or more chemical of impurities in the dosing hopper 201. In one more example, the dosing hopper 201 may be a screw pump hopper.
[028] The petroleum coke dosing system 200 further comprises one or more control valve 203, 204 connected to the dosing hopper 202, a conveyor 206 connected to the control valve via an air lock feeder 205. In one example, the one or more control valve 203, 204 may be one of a manual control valve 203 and an automatic control valve 204. Further in the example, the conveyer may be a screw conveyer comprising a variable displacement frequency motor. During operation the one or more control vale 203, 204 and the conveyer 206 may be configured to control the flow of one or more chemicals from the dosing hopper 202 to the mixing chamber. In one example, the one or more control vale 203, 204 may control the flow of one or more chemicals based on one or more of a rate of flow of chemical, a total percentage of vanadium in the petroleum coke, a total percentage of Sulphur in the petroleum coke, rate of flow of petroleum coke, a total amount of flue gas generated in the glass manufacturing furnace system, the composition of the a flow of air flue gas generated in the glass manufacturing furnace system, and the ratio of petroleum coke to air mixture. In one more example, during operation the conveyor 206 may control the flow of chemical based on the speed of conveyer 206, utilizing the variable frequency drive, may be based on a rate of flow of the petroleum coke in the glass manufacturing furnace system 100. Further, a rotary air lock feeder 205 avoids any air leakage or back pressure during operation and ensures smooth material flow
[029] Further in the embodiment, the petroleum coke dosing system 200 furthermore comprises a mixing chamber 208 connected to the conveyer 206 and a pneumatic screw pump assembly 115 connected to the mixing chamber 208 via a pneumatic screw pump hopper 114. The mixing chamber may be also connected to a blower 207. Further during operation, the mixing chamber 208 may receive the one or more chemicals for the conveyor 206 and mix the chemicals with air. Upon mixing, the pneumatic screw pump assembly 115 may receive the chemical air mixture from the mixing chamber via the pneumatic screw pump hopper 114. Upon receiving, the pneumatic screw pump assembly 115 may mix the petroleum coke-air mixture with chemical-air mixture, thereby dosing the petroleum coke, with one or more chemical, in a glass manufacturing furnace system.
[030] In one example, the air at low pressure may be supplied by the blower 207. In one more example, the total amount of air supplied by the blower 207 in a predefined time interval may be based on the total amount of air present in the petroleum coke air mixture, a total amount of chemical in the mixing chamber and an optimum amount of air required for complete combustion of the petroleum coke. Further, the pneumatic screw pump assembly 115 may further comprise a pneumatic screw pump and a secondary mixing chamber.
[031] 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 dosing system for dosing of petroleum coke, with one or more chemical, in a glass manufacturing furnace system.
[032] Some embodiments of the petroleum coke dosing system enable effective mixing and dosing of the chemical and petroleum coke
[033] Some embodiments of the petroleum coke dosing system enable controlled mixing
[034] Some embodiments of the petroleum coke dosing system enable dynamic change in a rate of mixing of petroleum coke and chemicals
[035] Some embodiments of the petroleum coke dosing system enable a homogenous mixing of petroleum coke and chemicals
[036] Some embodiments of the petroleum coke dosing system enable reduction in the side effects of burning of petroleum coke in the furnace of the glass manufacturing furnace system.
[037] Some embodiments of the petroleum coke dosing system save furnace, furnace refractories and regenerator, and remove Sulphur from flue gas.
[038] Although implementations for a petroleum coke dosing system for dosing of 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 a petroleum coke dosing system for dosing of petroleum coke, with one or more chemical, in a glass manufacturing furnace system.
,CLAIMS:
1. A petroleum coke dosing system (200) for dosing of petroleum coke, with one or more chemical, in a glass manufacturing furnace system (100), the petroleum coke dosing system (200) comprising:
a dosing hopper (202), wherein the dosing hopper (202) is configured to receive the one or more chemicals for dosing of petroleum coke;
one or more control valves (203, 204) connected to the dosing hoper (202), wherein the one or more control vales (203, 204) is configured to control the flow of the chemical based on one or more of a rate of flow of chemical, a total percentage of vanadium in the petroleum coke, a total percentage of Sulphur in the petroleum coke, rate of flow of petroleum coke;
a conveyor (206) connected to the control valves (203, 204), wherein the conveyor (206) is configured to receive a flow of chemical and convey the chemical for mixing, wherein a speed of the conveyer (206) is based on a rate of flow of the petroleum coke in the glass manufacturing furnace system (100);
a mixing chamber (208) connected to the conveyer (206 and a blower (207), wherein the mixing chamber (208) is configured to receive the chemical for the conveyor (206) and mix the chemicals with air, wherein the air is supplied by the blower (207); and
a pneumatic screw pump assembly (115) connected to the mixing chamber (208) via a pneumatic screw pump hopper (114), wherein the pneumatic screw pump assembly (115) is configured to receive a petroleum coke-air mixture from the mixing chamber (208) and mix the petroleum coke-air mixture with the chemical-air mixture, thereby dosing the petroleum coke, with one or more chemical, in a glass manufacturing furnace system (100).

2. The petroleum coke dosing system (200) as claimed in claim 1, wherein the one or more control vale (203, 204) is one of a manual control valve and an automatic control valve.

3. The petroleum coke dosing system (200) as claimed in claim 1, wherein the petroleum coke dosing system (200) further comprises an electrical hoist (201), and wherein the electrical hoist (201) is configured to hoist one or more bags of petroleum coke and pour the bags in the dosing hopper (202).

4. The petroleum coke dosing system (200) as claimed in claim 1, wherein the petroleum coke dosing system (200) further comprises an air lock feeder (205), and wherein the air lock feeder (205) is connected to the one or more control valve (203, 204) and the conveyor (206).

5. The petroleum coke dosing system (200) as claimed in claim 1, wherein the conveyer (206) is a screw conveyer, and wherein the conveyer (206) is further connected to a variable displacement frequency motor.

6. The petroleum coke dosing system as claimed in claim 1, wherein the pneumatic screw pump assembly (115) further comprises a pneumatic screw pump and a secondary mixing chamber.

7. The petroleum coke dosing system (200) as claimed in claim 1, wherein the one or more control vale (203, 204) is configured to control the flow of the chemical based on one or more of a total amount of flue gas generated in the glass manufacturing furnace system (100), the composition of the a flow of air flue gas generated in the glass manufacturing furnace system (100), and the ratio of petroleum coke to air mixture.

8. The petroleum coke dosing system (200) as claimed in claim 1, wherein the total amount of air supplied by the blower (207) in a predefined time interval and the speed of rotation of the blower is based on the total amount of air present in the petroleum coke air mixture and an optimum amount of air required for complete combustion of the petroleum coke.