Effective discharge of exhaust from submerged combustion melters and methods

• US 10,246,362 B2
• Filed: 06/22/2016
• Issued: 04/02/2019
• Est. Priority Date: 06/22/2016
• Status: Active Grant

• Current Assignee: Johns Manville Corporation (Berkshire Hathaway Incorporated)
• Original Assignee: Johns Manville Corporation (Berkshire Hathaway Incorporated)
• Inventors: Huber, Aaron Morgan
• Primary Examiner(s): Herring, Lisa L
• Application Number:
  US15/189,634
• Publication Number:
  US 20170369352A1
• Time in Patent Office: 1,014 Days
• CPC Class Codes: B01D 5/0012 Vertical tubes
• CPC Class Codes: B01D 5/0057 in combination with other processes
• CPC Class Codes: B01D 53/00 Separation of gases or vapours; Recovering vapours of volatile solvents from gases; Chemical or biological purification of waste gases, e.g. engine exhaust gases, smoke, fumes, flue gases, aerosols, recovery of volatile solvents by condensation B01D5/00; sublimation B01D7/00; cold traps, cold baffles B01D8/00; working-up undefined gaseous mixtures obtained by cracking hydrocarbon oils C10G70/00; cleaning coal gas C10K; working-up of natural gas, or synthetic natural gas, C10L3/10; separation of difficult-to-condense gases or air by liquefaction F25J; for investigating materials G01N30/00
• CPC Class Codes: C03B 2211/22 by direct combustion in the melt
• CPC Class Codes: C03B 5/04 in tank furnaces C03B5/02 takes precedence
• CPC Class Codes: C03B 5/20 Bridges, shoes, throats, or other devices for withholding dirt, foam, or batch
• CPC Class Codes: C03B 5/2356 Submerged heating, e.g. by using heat pipes, hot gas or submerged combustion burners bubblers C03B5/193
• CPC Class Codes: F23C 3/004 the chamber being arranged for submerged combustion F23C3/002 takes precedence
• CPC Class Codes: F23J 11/00 Devices for conducting smoke or fumes, e.g. flues chimney stacks E04H12/28; removing cooking fumes from domestic stoves or ranges F24C15/20 ; fume conduits of furnaces, kilns, ovens, or retorts F27D17/002
• CPC Class Codes: F23J 15/06 of coolers
• CPC Class Codes: F23J 2213/30 Specific materials
• CPC Class Codes: Y02P 40/50 Glass production, e.g. reusing waste heat during processing or shaping

Abstract

Submerged combustion methods and systems including a melter equipped with an exhaust passage through the ceiling or the sidewall having an aggregate hydraulic diameter. Submerged combustion burners configured to create turbulent conditions in substantially all of the material being melted, and produce ejected portions of melted material. An exhaust structure including a liquid-cooled exhaust structure defining a liquid-cooled exhaust chamber having a cross-sectional area greater than that of the exhaust stack but less than the melter. The exhaust passage and liquid-cooled exhaust structure configured to maintain temperature and pressure of the exhaust, and exhaust velocity through the exhaust passage and the exhaust structure, at values sufficient to prevent the ejected material portions of melted material from being propelled out of the exhaust structure as solidified material, and maintain any molten materials contacting the first interior surface molten so that it flows down the first interior surface into the melter.

Claims

1. A submerged combustion manufacturing system comprising:

a submerged combustion melter (SCM) equipped with one or more submerged combustion (SC) burners, the SCM having a length (L) and a width (W), a centerline (C), a midpoint (M), a sidewall structure having a north side (N) and a south side (S), the sidewall structure connecting a ceiling and a floor of the SCM, and one or more exhaust passages through the ceiling, the one or more exhaust passages having an aggregate hydraulic diameter;

the one or more submerged combustion burners configured to discharge combustion products under a level of material being melted in the SCM and create turbulent conditions in substantially all of the material being melted as well as ejected portions of melted material; and

an exhaust structure fluidly connecting the one or more exhaust passages with an exhaust stack, the exhaust structure comprising;

a liquid-cooled exhaust structure of height H1 fluidly connected to the one or more exhaust passages, the liquid-cooled exhaust structure defining a liquid-cooled exhaust chamber having a first interior surface, the liquid-cooled exhaust chamber having a cross-sectional area greater than that of the exhaust stack but less than the SCM,

the one or more exhaust passages and the liquid-cooled exhaust structure configured to maintain temperature and pressure of exhaust materials from the SCM, and exhaust velocity of the exhaust materials from the SCM through the liquid-cooled exhaust structure, at values sufficient to prevent the ejected portions of melted material from being propelled out of the liquid-cooled exhaust structure and into the exhaust stack as solidified material, and maintain any molten materials contacting the first interior surface molten so that it flows back down the first interior surface back into the SCM, and

a gas-cooled exhaust structure of height H7 fluidly connecting the liquid-cooled exhaust structure and the exhaust stack, the gas-cooled exhaust structure defining a gas-cooled exhaust chamber having a second interior surface, the gas-cooled exhaust structure consisting of a metal layer forming the second interior surface, the metal layer having one or more gas-cooled external surfaces, the gas-cooled exhaust structure devoid of refractory or other lining,

wherein H1 is greater than or equal to H7, and H7 is not 0.

2. The system of claim 1 wherein the gas-cooled exhaust chamber has a cross-sectional area substantially equal to the cross-sectional area of the liquid-cooled exhaust chamber.

3. The system of claim 1 comprising a feed inlet in a feed end of the sidewall structure, a molten product outlet in an exit end of the sidewall structure, wherein the one or more exhaust passages through the ceiling are positioned substantially centrally between the feed end and the exit ends.

4. The system of claim 1 wherein the one or more exhaust passages and the liquid-cooled exhaust chamber have a cross-sectional area configured so that the exhaust velocity of the exhaust materials is 25 ft./min. or less through the one or more exhaust passages and the liquid-cooled exhaust chamber.

5. The system of claim 1 wherein the one or more submerged combustion burners are configured to discharge the combustion products primarily non-laterally under the level of the material being melted in the SCM.

6. The system of claim 1 wherein the one or more submerged combustion burners are configured to discharge the combustion products primarily vertically under the level of the material being melted in the SCM.

7. The system of claim 1 wherein the sidewall structure comprises a feed end wall, an exit end wall, and two side walls, with each of the two side walls connected to both the feed end wall and the exit end wall.

8. The system of claim 1 wherein the liquid-cooled exhaust structure is constructed of metal having a service temperature higher than a temperature of the exhaust materials.

9. The system of claim 1 wherein the gas-cooled exhaust structure is constructed of metal having service a temperature higher than a temperature of the exhaust materials.

10. The system of claim 9 wherein the metal is one or more austenitic nickel-chromium super alloys, and the one or more gas-cooled external surfaces are steel.

11. The system of claim 1 wherein the liquid-cooled exhaust structure is configured for cooling using a liquid selected from the group consisting of water, organic liquids, inorganic liquids, and combinations thereof.

12. The system of claim 1 comprising an air inspirator fluidly connecting the liquid-cooled exhaust structure and the exhaust stack.

13. The system of claim 12 wherein the air inspirator is selected from the group consisting of one or more adjustable panels, and one or more adjustable hoods.

14. The system of claim 1 wherein the exhaust structure has a cross-sectional shape selected from the group consisting of rectangular, round, oval, trapezoidal, triangular, U-shaped, quadrangular, hexagonal, octagonal, and parabolic.

15. A submerged combustion manufacturing system comprising:

a submerged combustion melter (SCM) equipped with one or more submerged combustion (SC) burners, the SCM having a length (L) and a width (W), a centerline (C), a midpoint (M), a sidewall structure having a north side (N) and a south side (S), the sidewall structure connecting a ceiling and a floor of the SCM, and one or more exhaust passages through the sidewall structure, the one or more exhaust passages having an aggregate hydraulic diameter;

the one or more submerged combustion burners configured to discharge combustion products under a level of material being melted in the SCM and create turbulent conditions in substantially all of the material being melted as well as ejected portions of melted material; and

an exhaust structure fluidly connecting the one or more exhaust passages with an exhaust stack, the exhaust structure comprising;

a liquid-cooled exhaust structure of height H1 fluidly connected to the one or more exhaust passages, the liquid-cooled exhaust structure defining a liquid-cooled exhaust chamber having a first interior surface, the liquid-cooled exhaust chamber having a cross-sectional area greater than that of the exhaust stack but less than the SCM,

the one or more exhaust passages and the liquid-cooled exhaust structure configured to maintain temperature and pressure of exhaust materials from the SCM, and exhaust velocity of the exhaust materials from the SCM through the liquid-cooled exhaust structure, at values sufficient to prevent the ejected portions of melted material from being propelled out of the liquid-cooled exhaust structure and into the exhaust stack as solidified material, and maintain any molten materials contacting the first interior surface molten so that it flows back down the first interior surface back into the SCM, and

a gas-cooled exhaust structure of height H7 fluidly connecting the liquid-cooled exhaust structure and the exhaust stack, the gas-cooled exhaust structure defining a gas-cooled exhaust chamber having a second interior surface, the gas-cooled exhaust structure consisting of a metal layer forming the second interior surface, the metal layer having one or more gas-cooled external surfaces, the metal layer forming the second interior surface devoid of refractory or other lining,

wherein H1 is greater than or equal to H7, and H7 is not 0.

16. The system of claim 15 wherein the one or more exhaust passages and the liquid-cooled exhaust chamber have a cross-sectional area configured so that the exhaust velocity of the exhaust materials is 25 ft./min. or less through the liquid-cooled exhaust chamber.