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:
SYSTEM AND METHOD TO OVERCOME AND BURN SETTLED PETROLEUM COKE IN GLASS MANUFACTURING FURNACE

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 petcoke fired glass manufacturing furnace and in particular to system and method for overcoming and burning petroleum coke settled during burner reversal in a petroleum coke fired glass manufacturing furnace.
BACKGROUND
[002] Petroleum coke (Petcoke) is a black-colored solid composed primarily of carbon, and may contain limited amounts of elemental forms of 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-cooking and delayed coking. Petcoke may be combusted as fuel in industrial and power generating plants. Cement plants and power plants are currently the two greatest consumers of petcoke. In many countries, the high sulfur metals, and non-volatile inorganic compounds content may limit the petcoke in a coal/petcoke blend in a plant designed for coal.
[003] Generally, manufacturing of glass has been done based utilizing different type of furnace and using different types of fuels, depending on the final characteristics of the product and also with regard to the thermal efficiency of the processes. Conventionally, the fuel used to melt glass was 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. Generally, alternating burners are used for combustion of petcoke in manufacturing of glass in a predefined cycle but such cyclic use of burners result in a phenomenon termed as “petroleum coke settling” phenomenon. The petroleum coke settling phenomenon fine particulate matter of petcoke settle to the bottom of the pipes during reversal of the burners causing blockage of the pipes. Conventional systems for overcoming petroleum coke settling fail when implemented in a petroleum coke fired furnace utilized for manufacturing of glass. Furthermore, the convention system failed to burn any settled petcoke, ( thus resulting in a secondary settling phenomenon within the furnace ). In this the unburned petcoke settles on the glass being manufactured in turn degrading the glass quality.

SUMMARY
[004] Before the present system(s) and method for overcoming and burning petroleum coke settled during burner reversal in petroleum coke fired glass manufacturing furnace, 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 overcoming and burning petroleum coke settled during burner reversal in petroleum coke fired glass manufacturing furnace. 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 another implementation, a method for overcoming and burning petroleum coke settled during burner reversal in petroleum coke fired glass manufacturing furnace is disclosed. In one embodiment, the method may comprise supplying a petroleum coke- air mixture to the plurality of burners via a reversal system valve for a first time interval. Upon suppling the petroleum coke- air mixture, the method may comprise, switching-off the flow of petroleum coke-air mixture upon completion of the first time interval utilizing the reversal system valve. Further to switching-off the supply of the petroleum coke- air mixture, the method may comprise, supplying a secondary air from a roots blower via pneumatic valves upon completion of the first time interval to clean settled petroleum coke, thereby overcoming petroleum coke settling during burner reversal. The method may further comprise, suppling combustion air from a combustion blower for the first time interval and the second time interval for burning petroleum coke settled during first interval in the glass manufacturing furnace.
[006] In one implementation, the system for overcoming and burning petroleum coke settled during burner reversal in a petroleum coke fired glass manufacturing furnace is disclosed. In one embodiment, the system may comprise a reversal system valve connected to a plurality of burners. Further, the reversal system valve may be configured to reverse the flow of pet coke air mixture between the plurality of burners. Furthermore, during operation the reversal system valve may be configured to supply the petroleum coke- air mixture to the plurality of burners for a first time interval, and switch-off the flow of petroleum coke- air mixture upon completion of the first time interval. The system may further comprise pneumatic valves connected to the reversal system valve, a roots blower and plurality of burners for supplying secondary air during burner reversal. Further, during operation the pneumatic valve is configured to initiate the supply of the secondary air for a second time interval upon completion of the first time interval to clean settled petroleum coke and overcoming petroleum coke settling during burner reversal. The system may furthermore comprise a combustion blower connected to the plurality of burner via a regenerator system for suppling combustion air. Further, during operation the combustion blower may be configured to supply combustion air for the first time interval and the second time interval for burning petroleum coke settled during first interval.
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 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 petcoke fired glass melting furnace comprising a system for overcoming and burning petroleum coke settled during burner reversal in petroleum coke fired glass manufacturing furnace, in accordance with an embodiment of the present subject matter.
[010] Figure 2 illustrates a method for overcoming and burning petroleum coke settled during burner reversal in petroleum coke fired glass manufacturing furnace, in accordance with an embodiment of the present subject matter.
DETAILED DESCRIPTION
[011] 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 overcoming and burning petroleum coke settled during burner reversal in petroleum coke fired glass manufacturing furnace, 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 overcoming and burning petroleum coke settled during burner reversal in petroleum coke fired glass manufacturing furnace are now described. The disclosed embodiments overcoming and burning petroleum coke settled during burner reversal in petroleum coke fired glass manufacturing furnace are merely examples of the disclosure, which may be embodied in various forms.
[012] 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 overcoming and burning petroleum coke settled during burner reversal in petroleum coke fired glass manufacturing furnace. However, one of ordinary skill in the art will readily recognize that the present disclosure overcoming and burning petroleum coke settled during burner reversal in petroleum coke fired glass manufacturing furnace 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.
[013] 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 section comprises vanadium, and sodium. Generally, alternating burners are used for combustion of petcoke in manufacturing of glass in a predefined cycle but such cyclic use of burners result in a phenomenon termed as “petroleum coke settling”. In the petroleum coke settling phenomenon fine particulate matter of petcoke settle to the bottom of the pipes during reversal of the burners causing blockage of the pipes. Conventional systems for overcoming petroleum coke settling fail when implemented in a petroleum coke fired furnace. Furthermore the conventional system do not burn the petcoke settled in the pipes because of unavailability of combustion air. This cause settlement of unburned petcoke particles on top of glass in the furnace. Thus degrading the quality of glass manufactured. In order to overcome the above technical problems, the present subject matter discloses a system and method for overcoming and burning petroleum coke settled during burner reversal in a petroleum coke fired glass manufacturing furnace
[014] In one implementation, a system and method for overcoming and burning petroleum coke settled during burner reversal in a petroleum coke fired glass manufacturing furnace comprise a reversal system valve connected to a plurality of burners to reverse the flow of pet coke air mixture between the plurality of burner, pneumatic valves connected to the reversal system valve, a roots blower and plurality of burners for supplying secondary air during burner reversal, and a combustion blower connected to the plurality of burner via a regenerator system for suppling combustion air.
[015] In the said implementation, during operation a petroleum coke- air mixture may be supplied to the plurality of burners via the reversal system valve for a first time interval and switched-off upon completion of the first time interval utilizing the reversal system valve. Further to switching-off, a secondary air may be supplied from a roots blower via pneumatic valves for a second time interval upon completion of the first time interval to clean settled petroleum coke, thereby overcoming petroleum coke settling during burner reversal. Upon supplying secondary air, combustion air may be supplied from a combustion blower for the first time interval and the second time interval for burning petroleum coke settled during first interval in the glass manufacturing furnace. Further, the burner reversal may be performed upon completion of the second time interval
[016] Now referring to Figure 1, figure 1 illustrates a petroleum coke (petcoke) fired glass melting furnace system 100, in accordance with an embodiment of the present subject matter, is disclosed. Further, table 1 below, disclosed the elements of the glass melting furnace system 100.
Table 1: List of elements
Element Number Definition Element Number Definition
101 Big bag unloading machine 111 Manual slide gate
102, 104, 113 Rotary Air lock feeder 112 Screw conveyor with VFD
103 Rotary screen 118 Return line valve
105, 114 Pneumatic Screw hopper 119a, 119b Pneumatic valves
106,115 Pneumatic Screw Pump 120 Reversal system valve
107, 116 Roots blower 121A, 121B Petcoke burner
108, 117 Dust collector 122 Roots blower
109 Service silo 123 Furnace
110A, 110B Single shaft agitator 124 Chimney
126 Combustion blower 125 Regenerator
127 Port
[017] In the embodiment the glass melting furnace system 100 is as follows. The pet 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 pet 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 petcoke. 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 petcoke. 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 petcoke 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 valve 120 and second pneumatic diverter or return line valve 118 conveys material to service silo 109. Further, the reversal system valve 120 in an alternating fashion diverts petcoke to the burner 119a &119b. Since pet coke has low volatiles it takes longer time to ignite. The burners are provided with swirled to ensure the petcoke 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] Further Figure 1 illustrates a system for overcoming and burning petroleum coke settled during burner reversal in petroleum coke fired glass manufacturing furnace, in accordance with an embodiment of the present subject matter. In one example embodiment of the system, 2 minutes before actual reversal operation or 18 minutes after actual reversal operation petcoke-air mixture flow is switched off, but the combustion air supply from the combustion air blower is kept on. Further, the secondary air supply is provided by the roots blower for two minutes after switching of the petcoke-air mixture supply. Thus the early simultaneous supply of secondary air and combustion air enables cleaning of settled petcoke and further burning of the settled petcoke. After this, reversal take place from (Left) to (Right) or vice versa. In one example, reversal may be understood as stopping the flow of petcoke air mixture and combustion air to one side and initiated on the other side.
[020] In one more implementation, the system for overcoming and burning petroleum coke settled during burner reversal in petroleum coke fired glass manufacturing furnace is disclosed. In the implementation, the system may comprise a reversal system valve 120 connected to a plurality of burners 121A, 121B to reverse the flow of pet coke air mixture between the plurality of burners 121A, 121B, pneumatic valves 119a, 119b connected to the reversal system valve 120, and roots blower 122 for supplying secondary air during burner reversal, and a combustion blower 126 connected via a regenerator system 125 for supplying combustion air. In one example, the secondary air acts as a cleaning agent, which cleans the petcoke settled in the pipe lines.
[021] In the implementation, during operation the reversal system valve 120 may supply the petroleum coke- air mixture to first set of burners 121A for a first time interval, and switch-off the flow of petroleum coke- air mixture to the first set of burners 121A upon completion of the first time interval in order to initiate the burner reversal. In one example, the first time interval may be 18 minutes after previous burner reversal or 2 minutes before next reversal. Upon switching off the supply to the burners, the pneumatic valve 119a may initiate the supply of the secondary air to the first set of burners 121A, to clean settled petroleum coke and overcoming petroleum coke settling during burner reversal. In one example, the supply of secondary air may be switched off to the first set of burners 121A upon completion of the second time interval. In one example, the second time interval may be 2 minutes. Further, the combustion blower may supply combustion air to the first set of burners 121A for total of the first time interval and the second time interval for burning petroleum coke settled during first interval.
[022] In the said implementation, upon completion of the second time interval, the reversal system valve 120 and the combustion blower 126 may perform burner reversal. In one example, the burner reversal comprises initiating the supply of the petroleum coke- air mixture and the combustion air to the second set of burners 121B. In one example, the burner reversal may be performed after every twenty minutes, i.e. at the end of second interval. Upon burner reversal, the reversal system valve 120, the pneumatic valves 119b and a combustion blower 126 may repeat the above described steps to overcome petcoke settling and burning settled pet coke. Further to repetition of the above described steps, burner reversal may again be executed. In one example, this burner reversal may also be performed after twenty minutes. Further, it may be understood that the above description may be performed in a cyclic manner in order to overcome petroleum coke settling during burner reversal and burning of the settled petcoke in petroleum coke fired glass manufacturing furnace.
[023] 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.
[024] Some embodiments of the system and the method completely remove petcoke settling.
[025] Some embodiments of the system and the method enable combustion of the settled petcoke.
[026] Some embodiments of the system and the method reduce degradation of glass being manufactured.
[027] Referring now to Figure 2, a method 200 for overcoming and burning petroleum coke settled during burner reversal in petroleum coke fired glass manufacturing furnace is shown, in accordance with an embodiment of the present subject matter. The order in which the method 200 for overcoming and burning petroleum coke settled during burner reversal in petroleum coke fired glass manufacturing furnace is described is not intended to be construed as a limitation, and any number of the described method blocks can be combined in any order to implement the method 200 or alternate methods. Additionally, individual blocks may be deleted from the method 200 without departing from the spirit and scope of the subject matter described herein. Furthermore, the method can be implemented in any suitable hardware, software, firmware, or combination thereof. However, for ease of explanation, in the embodiments described below, the method 200 for overcoming and burning petroleum coke settled during burner reversal in petroleum coke fired glass manufacturing furnace may be considered to be implemented in the above described system 100.
[028] At block 202, a petroleum coke-air mixture may be supplied to the plurality of burners via a reversal system valve for a first time interval.
[029] At block 204, the flow of petroleum coke-air mixture may be switched-off upon completion of the first time interval utilizing the reversal system valve.
[030] At block 206, a secondary air may be supplied from a roots blower via pneumatic valves for a second time interval upon completion of the first time interval to clean settled petroleum coke, thereby overcoming petroleum coke settling during burner reversal. In one example, the supply of secondary air may be switched–off upon completion of the second time interval utilizing the pneumatic valve.
[031] At block 208, combustion air from a combustion blower may be supplied for complete first time interval and the second time interval for burning petroleum coke settled during first interval in the glass manufacturing furnace.
[032] 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 system for overcoming and burning petroleum coke settled during burner reversal in petroleum coke fired glass manufacturing furnace. Although implementations of the system and the methods for overcoming and burning petroleum coke settled during burner reversal in petroleum coke fired glass manufacturing furnace, 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 overcoming and burning petroleum coke settled during burner reversal in petroleum coke fired glass manufacturing furnace.

,CLAIMS:
1. A method for overcoming and burning petroleum coke settled during burner reversal in petroleum coke fired glass manufacturing furnace, the method comprising:
supplying a petroleum coke- air mixture to the plurality of burners (121A) via a reversal system valve (120) for a first time interval;
switching-off the flow of petroleum coke- air mixture upon completion of the first time interval utilizing the reversal system valve (120);
supplying a secondary air from a roots blower (122) via one of the pneumatic valve (119a) for a second time interval upon completion of the first time interval to clean settled petroleum coke, thereby overcoming petroleum coke settling during burner reversal;
suppling combustion air from a combustion blower (126) for the first time interval and the second time interval for burning petroleum coke settled during first interval in the glass manufacturing furnace.

2. The method of claim 1, further comprising performing burner reversal upon completion of the second time interval.

3. The method of claim 1, further comprising switching-off the supply of secondary air upon completion of the second time interval utilizing the pneumatic valve (119a).

4. The method of claim 2, wherein burner reversal is performed every twenty minutes, wherein the burner reversal comprises the supply the petroleum coke- air mixture and the combustion air mixture to other burners from the plurality of burners (121A, 121B).

5. The method of claim 1, wherein the first time interval is one of 18 minutes after previous burner reversal or 2 minutes before next reversal.

6. The method of claim 1, wherein the second time interval is 2 minutes.

7. A system for overcoming and burning petroleum coke settled during burner reversal in petroleum coke fired glass manufacturing furnace, the system comprising:
a reversal system valve (120) connected to a plurality of burners (121A), wherein the reversal system valve (120) is configured to reverse the flow of pet coke air mixture between the plurality of burners (121A), wherein during operation the reversal system valve (120) is configured to supply the petroleum coke- air mixture to the plurality of burners (121A) for a first time interval, and wherein the reversal system valve (120) is configured to switch-off the flow of petroleum coke- air mixture upon completion of the first time interval;
pneumatic valves (119a, 119b) connected to the reversal system valve (120), an roots blower (122) and plurality of burners (121A, 121B) for supplying secondary air during burner reversal, wherein during operation the pneumatic valve (119a) is configured to initiate the supply of the secondary air for a second time interval, upon completion of the first time interval to clean settled petroleum coke and overcoming petroleum coke settling during burner reversal; and
a combustion blower (126) connected to the plurality of burner (121A, 121B) via a regenerator system (125) for suppling combustion air; wherein during operation the combustion blower (126) is configured to supply combustion air for the first time interval and the second time interval for burning petroleum coke settled during first interval.

8. The system of claim 7, wherein during operation upon completion of the second time interval, the reversal system valve (120) and the combustion blower (126) are configured to perform burner reversal.
9. The system of claim 8, wherein the system is configured to perform burner reversal every twenty minutes.
10. The system of claim 7, wherein the first time interval is one of 18 minutes after previous burner reversal or 2 minutes before next reversal.
11. The system of claim 7, wherein the second time interval is 2 minutes.