US4248615A — Pollution abating, energy conserving glass manufa…

Claim 1

Independent Claim 167 words

In a glass manufacturing process comprising, combining glass forming batch ingredients and water into free water containing glass batch agglomerates, continuously directly contacting glass batch agglomerates in a vertical bed with flue gases from a glass melting furnace so as to preheat agglomerates, discharging said preheated agglomerates from a lower portion of said bed, charging said preheated agglomerates to said melting furnace and melting said charged agglomerates therein, the improvement wherein said free water containing glass batch agglomerates are hydrologically unstable and further comprising accumulating a predetermined amount of said hydrologically unstable agglomerates in a preconditioning chamber so as to form a preconditioning bed of a predetermined height, directing flue gases from said vertical bed into said preconditioning chamber and passing said gases through said preconditioning bed so as to heat said preconditioning bed of hydrologically unstable agglomerates for a sufficient period of time to form a hydrologically stabilized bed of agglomerates, discharging the agglomerates of said hydrologically stabilized bed and supplying them to said vertical bed.

Claim 2

Dependent Claim 167 words

In a glass manufacturing process comprising, combining glass forming batch ingredients and water into free water containing glass batch agglomerates, continuously directly contacting glass batch agglomerates in a vertical bed with flue gases from a glass melting furnace so as to preheat agglomerates, discharging said preheated agglomerates from a lower portion of said bed, charging said preheated agglomerates to said melting furnace and melting said charged agglomerates therein, the improvement wherein said free water containing glass batch agglomerates are hydrologically unstable and further comprising accumulating a predetermined amount of said hydrologically unstable agglomerates in a preconditioning chamber so as to form a preconditioning bed of a predetermined height, directing flue gases from said vertical bed into said preconditioning chamber and passing said gases through said preconditioning bed so as to heat said preconditioning bed of hydrologically unstable agglomerates for a sufficient period of time to form a hydrologically stabilized bed of agglomerates, discharging the agglomerates of said hydrologically stabilized bed and supplying them to said vertical bed.

Claim 3

Dependent Claim 13 words

The process of claim 1 wherein said preconditioning bed is a static bed.

Claim 4

Dependent Claim 34 words

The process of claim 1 wherein said hydrologically unstable agglomerates are accumulated in at least two, separate preconditioning chambers, said chambers being in a parallel flow arrangement and disposed downstream of said vertical bed.

Claim 5

Dependent Claim 26 words

The process of claim 3 wherein said flue gases are directed from said vertical bed to said chambers and exhausted therefrom in a parallel flow path.

Claim 6

Dependent Claim 21 words

The process of claim 1 wherein said height is less than the inherent aggregate forming height of said hydrologically unstable agglomerates.

Claim 7

Dependent Claim 21 words

The process of claim 1 wherein said height is greater than the inherent aggregate forming height of said hydrologically unstable agglomerates.

Claim 8

Dependent Claim 20 words

The process of claim 3 wherein said hydrologically unstable agglomerates are sequentially accumulated in said parallel flow arranged preconditioning chambers.

Claim 9

Dependent Claim 49 words

The process of claim 1 wherein the weight ratio of free water in the agglomerates of the upper layer of said preconditioning bed, at the time of discharging said hydrologically stabilized bed, relative to the free water of said agglomerates accumulated in said chamber is less than about 0.96%.

Claim 10

Dependent Claim 84 words

The process of claim 6 wherein the wet bulb temperature of the flue gases from the melting furnace is in excess of about 130° F. (54° C.) and said flue gases, prior to being directed into said preconditioning chambers, are diluted with air to decrease the web bulb temperature thereof and the height of the said preconditioning bed is in excess of the adjusted imminent aggregate forming height corresponding to the wet bulb temperature of the diluted flue gases directed into said preconditioning chamber.

Claim 11

Dependent Claim 40 words

The process of claim 9 wherein the wet bulb temperature of such diluted flue gases is between about 100° F. to about 130° F. (38° C.-54° C.) and the dry bulb temperature is less than about 500° F. (260° C.).

Claim 12

Dependent Claim 57 words

The process of claim 1 wherein said agglomerates are pellets of batch ingredients for a glass containing Na 2 O in an amount in excess of about 5% by weight, on a theoretical oxide basis, and said height is in excess of about 2 inches (about 5 cm) and less than about 9 inches (about 23 cm).

Claim 13

Dependent Claim 21 words

The process of claim 11 wherein said pellets contain about 10 to about 15% by weight (dry basis) of free water.

Claim 14

Dependent Claim 46 words

The process of claim 12 wherein the ratio of the water content of pellets in the upper layer of said preconditioning bed when discharged relative to the water content of said pellets accumulated to initially form said bed falls approximately within area ABCED of FIG. 3.

Claim 15

Dependent Claim 13 words

The process of claim 13 wherein said glass is a soda-lime aluminoborosilicate glass.

Claim 16

Dependent Claim 19 words

The process of claim 14 wherein substantially all the soda is supplied to the batch by a sodium carbonate.

Claim 17

Dependent Claim 26 words

The process of claim 3 wherein the height of said preconditioning beds formed in said chambers is significantly less than the height of said vertical bed.

Claim 18

Dependent Claim 33 words

The process of claim 1 wherein the flow of flue gases passing through said preconditioning bed consists of passing said gases upwardly through the bed and then exhausting said gases from said chamber.

Claim 19

Dependent Claim 110 words

An energy efficient, pollution abating, glass manufacturing process comprising, forming separate beds of free-water containing hydrologically unstable glass batch agglomerates, discharging the agglomerates of said beds, after at least some heating, and supplying them into a shaft type preheating chamber having a vertical bed of agglomerates therein, releasing dry, further heated agglomerates from said vertical bed, charging said dry, further heated agglomerates to a combustion fired melting furnace, melting said agglomerates therein while conveying flue gases from said furnace to said chamber, through said vertical bed so as to further heat said agglomerates, and then from said vertical bed through said separate beds so as to heat the agglomerates therein.

Claim 20

Dependent Claim 110 words

An energy efficient, pollution abating, glass manufacturing process comprising, forming separate beds of free-water containing hydrologically unstable glass batch agglomerates, discharging the agglomerates of said beds, after at least some heating, and supplying them into a shaft type preheating chamber having a vertical bed of agglomerates therein, releasing dry, further heated agglomerates from said vertical bed, charging said dry, further heated agglomerates to a combustion fired melting furnace, melting said agglomerates therein while conveying flue gases from said furnace to said chamber, through said vertical bed so as to further heat said agglomerates, and then from said vertical bed through said separate beds so as to heat the agglomerates therein.

Claim 21

Dependent Claim 53 words

The process of claim 18 wherein said separate beds are heated with said flue gases for a sufficient period of time to ensure that they will not form process disabling aggregates in said preheating chamber but a period of time insufficient to allow said respective, separate beds themselves to form process disabling aggregates.

Claim 22

Dependent Claim 12 words

The process of claim 19 wherein said separate beds are static beds.

Claim 23

Dependent Claim 30 words

The process of claim 20 wherein the agglomerates of said vertical bed flow gravitationally downwardly and said flue gases are conveyed through said vertical bed in a counter-current flow manner.

Claim 24

Dependent Claim 12 words

The process of claim 18 wherein said separate beds are sequentially formed.

Claim 25

Dependent Claim 33 words

The process of claim 22 wherein said separate beds are formed adjacently upwardly of said preheating chamber and flue gases from said chamber are conveyed to said beds in a parallel flow manner.

Claim 26

Dependent Claim 10 words

The process of claim 18 wherein said agglomerates are pellets.

Claim 27

Dependent Claim 19 words

The process of claim 24 wherein said pellets have a size between about 3/8 inch to about 5/8 inch.

Claim 28

Dependent Claim 23 words

The process of claim 24 wherein said pellets are heated in said vertical bed to a temperature in excess of about 500° C.

Claim 29

Dependent Claim 28 words

The process of claim 18 or 20 or 22 or 26 wherein said flue gases are diluted with air prior to being conveyed through said respective separate beds.

Claim 30

Dependent Claim 26 words

The process of claim 22 wherein on a theoretical dry, oxide basis said pellets contain about 10 to about 20% by weight of Na 2 O.

Claim 31

Dependent Claim 28 words

The process of claim 28 wherein said Na 2 O is supplied by at least one member selected from the group consisting of caustic and a sodium carbonate.

Claim 32

Dependent Claim 29 words

The process of claim 1 or claim 18 wherein the agglomerates are supplied by dropping said agglomerates downwardly a distance of at least about 1 foot (about 30.5 cm).

Claim 33

Dependent Claim 25 words

The process of claim 2 wherein said agglomerates are pellets and said pellets are accumulated and said hydrologically stabilized bed discharged in a cyclic manner.

Claim 34

Dependent Claim 104 words

A glass manufacturing process comprising cyclically forming separate beds of free-water containing, hydrologically unstable glass batch agglomerates, and, after at least some heating, discharging the agglomerates of said beds, supplying them into a shaft type preheating chamber having vertical bed of agglomerates therein, releasing dry, further heated agglomerates from said vertical bed, charging said dry, further heated agglomerates to a glass melter and melting said agglomerates therein, while conveying a gaseous heating medium to said chamber, through said vertical bed so as to further heat said agglomerates and then from said vertical bed through said separate beds so as to heat the agglomerates therein.

Claim 35

Dependent Claim 104 words

A glass manufacturing process comprising cyclically forming separate beds of free-water containing, hydrologically unstable glass batch agglomerates, and, after at least some heating, discharging the agglomerates of said beds, supplying them into a shaft type preheating chamber having vertical bed of agglomerates therein, releasing dry, further heated agglomerates from said vertical bed, charging said dry, further heated agglomerates to a glass melter and melting said agglomerates therein, while conveying a gaseous heating medium to said chamber, through said vertical bed so as to further heat said agglomerates and then from said vertical bed through said separate beds so as to heat the agglomerates therein.

Claim 36

Dependent Claim 11 words

The process of claim 32 wherein said melting is done electrically.

Claim 37

Dependent Claim 39 words

The process of claim 33 wherein said gaseous heating medium conveyed to said chamber contain combustion products and has a wet bulb temperature in excess of about 100° F. (38° C.) and less than about 130° F. (54° C.).

Claim 38

Dependent Claim 33 words

The process of claim 32 wherein said separate beds are heated for a sufficient period of time to ensure that no massive aggregates form in either said separate beds or said vertical bed.

Claim 39

Dependent Claim 12 words

The process of claim 35 wherein said separate beds are static beds.

Claim 40

Dependent Claim 22 words

The process of claim 33 wherein said gaseous heating medium is diluted with air prior to being conveyed through said respective beds.

Claim 41

Dependent Claim 35 words

The process of claim 37 wherein said separate beds are formed adjacently upwardly of said preheating chamber and said gaseous heating medium from said chamber is conveyed to said beds in a parallel flow manner.

Claim 42

Dependent Claim 10 words

The process of claim 36 wherein said agglomerates are pellets.

Claim 43

Dependent Claim 13 words

The process of claim 39 wherein said gaseous heating medium comprises combustion products.

Claim 44

Dependent Claim 22 words

The process of claim 40 wherein said gaseous heating medium is diluted with prior to being conveyed through said respective separate beds.

Claim 45

Dependent Claim 23 words

The process of claim 41 wherein said pellets are heated in said vertical bed to a temperature in excess of about 500° C.

Claim 46

Dependent Claim 26 words

The process of claim 41 wherein on a theoretical dry, oxide basis said pellets contain about 10 to about 20% by weight of Na 2 O.

Claim 47

Dependent Claim 28 words

The process of claim 43 wherein said Na 2 O is supplied by at least one member selected from the group consisting of caustic and a sodium carbonate.

Claim 48

Dependent Claim 176 words

In a glass manufacturing process comprising, combining glass forming batch ingredients and water into free water containing, glass batch agglomerates, continuously directly contacting glass batch agglomerates in a vertical bed with gaseous combustion products so as to preheat the agglomerates, discharging said preheated agglomerates from a lower portion of said bed, charging said preheated agglomerates to a melting furnace and melting said charged agglomerates therein, the improvement wherein said free water containing agglomerates are hydrologically unstable and preventing said agglomerates from forming process disabling aggregates by supplying said hydrologically unstable agglomerates to a preconditioning chamber so as to form a preconditioning bed of progressively increasing height, discontinuing the supply to said chamber and directing said gaseous combustion products from said vertical bed into said preconditioning chamber and passing said gaseous combustion products through said preconditioning bed so as to heat said preconditioning bed of hydrologically unstable agglomerates for a sufficient period of time to form a hydrologically stabilized bed of agglomerates, discharging the agglomerates to said hydrologically stabilized bed and supplying them to said vertical bed.

Claim 49

Dependent Claim 176 words

In a glass manufacturing process comprising, combining glass forming batch ingredients and water into free water containing, glass batch agglomerates, continuously directly contacting glass batch agglomerates in a vertical bed with gaseous combustion products so as to preheat the agglomerates, discharging said preheated agglomerates from a lower portion of said bed, charging said preheated agglomerates to a melting furnace and melting said charged agglomerates therein, the improvement wherein said free water containing agglomerates are hydrologically unstable and preventing said agglomerates from forming process disabling aggregates by supplying said hydrologically unstable agglomerates to a preconditioning chamber so as to form a preconditioning bed of progressively increasing height, discontinuing the supply to said chamber and directing said gaseous combustion products from said vertical bed into said preconditioning chamber and passing said gaseous combustion products through said preconditioning bed so as to heat said preconditioning bed of hydrologically unstable agglomerates for a sufficient period of time to form a hydrologically stabilized bed of agglomerates, discharging the agglomerates to said hydrologically stabilized bed and supplying them to said vertical bed.

Claim 50

Dependent Claim 16 words

The process of claim 45 wherein said preconditioning bed is a static bed while being heated.

Claim 51

Dependent Claim 29 words

The process of claim 45 wherein said hydrologically unstable agglomerates are pellets and wherein said pellets are sequentially supplied, and the supply discontinued, to at least two preconditioning chambers.

Claim 52

Dependent Claim 20 words

The process of claim 46 wherein the height of said static bed is between about 2 to about 9 inches.

Claim 53

Dependent Claim 51 words

The process of claim 45 wherein the combustion products are diluted with air prior to passage through said preconditioning bed to decrease the wet bulb temperature thereof and the height of said bed is less than the adjusted inherent aggregate forming height corresponding to the psychrometry of the diluted combustion products.

Claim 54

Dependent Claim 24 words

The process of claim 45 and further including repeating said steps of supplying, discontinuing the supply, directing and discharging in a cyclic, continuous manner.

Claim 55

Dependent Claim 112 words

The process of claim 1 or 18 or 32 or 45 wherein the height of said discharged bed(s) is no greater than the height at which aggregates will form when said bed is totally dryed by direct contact with a gaseous heating medium comprising combustion products and having a dry bulb temperature of about 350° F. (177° C.) and a wet bulb temperature of about 80° F. (26°-27° C.), but greater than the height at which such aggregates will form when so dried with a gaseous heating medium comprising combustion products and having a dry bulb temperature of about 350° F. and a wet bulb temperature of about 137° F. (58° C.).

Claim 56

Dependent Claim 156 words

A glass manufacturing process comprising discharging a supply of free water containing, hydrologically unstable, glass batch agglomerates gravitationally downwardly, discontinuing said discharging at a predetermined interval and intercepting said gravitationally downwardly discharged supply so as to form said supply into a shallow static bed of substantially uniform height, directly heating said static bed so as to remove at least some free water from the agglomerates and convert said bed to a hydrologically stabilized bed, discharging the agglomerates of said stabilized bed downwardly unto a vertical bed, said vertical bed being maintained at a predetermined minimum height, gravitationally flowing the discharged agglomerates generally downwardly through said vertical bed, heating said vertical bed, including said generally downwardly flowing discharged agglomerates to an elevated temperature by direct contact with a gaseous heating medium passing through said vertical bed, supplying said heated flowing agglomerates after flowing through said vertical bed to a glass melting furnace and melting said agglomerates therein.

Claim 57

Dependent Claim 156 words

A glass manufacturing process comprising discharging a supply of free water containing, hydrologically unstable, glass batch agglomerates gravitationally downwardly, discontinuing said discharging at a predetermined interval and intercepting said gravitationally downwardly discharged supply so as to form said supply into a shallow static bed of substantially uniform height, directly heating said static bed so as to remove at least some free water from the agglomerates and convert said bed to a hydrologically stabilized bed, discharging the agglomerates of said stabilized bed downwardly unto a vertical bed, said vertical bed being maintained at a predetermined minimum height, gravitationally flowing the discharged agglomerates generally downwardly through said vertical bed, heating said vertical bed, including said generally downwardly flowing discharged agglomerates to an elevated temperature by direct contact with a gaseous heating medium passing through said vertical bed, supplying said heated flowing agglomerates after flowing through said vertical bed to a glass melting furnace and melting said agglomerates therein.

Claim 58

Dependent Claim 26 words

The process of claim 52 wherein said vertical bed is maintained by discharging agglomerates of at least one other separate stabilized bed unto said vertical bed.

Claim 59

Dependent Claim 26 words

The process of claim 52 wherein the ratio of the height of said static bed to said minimum height (times 100) is less than about 5%.

Claim 60

Dependent Claim 12 words

The process of claim 52 wherein said heating medium comprises combustion products.

Claim 61

Dependent Claim 19 words

The process of claim 52 wherein said static bed is directly heated with a heating medium comprising combustion products.

Claim 62

Dependent Claim 20 words

The process of claim 55 or 56 wherein said combustion products are flue gases from a combustion fired glass melter.

Claim 63

Dependent Claim 68 words

The process of claim 52 wherein said hydrologically unstable agglomerates during drying undergo a decrease in strength to a minimum value and then an increase in strength and wherein said static bed is heated for a sufficient period of time to remove free water such that the strength of the agglomerates have at least reached said minimum at which time said agglomerates are discharged to said vertical bed.

Claim 64

Dependent Claim 69 words

The process of claim 58 wherein the supplied free water containing agglomerates have an initial water content, W i , and the agglomerates in the upper layer of said static bed have a water content, W f , at any point in time during said direct heating and wherein said agglomerates are discharged to said vertical bed when the ratio W f /W i is less than about 0.6.

Claim 65

Dependent Claim 47 words

The process of claim 52 wherein said gaseous heating medium comprises combustion products, and wherein said combustion products after passage through said vertical bed are combined with air to form a gaseous drying medium and wherein said static bed is directly heated with said gaseous drying medium.

Claim 66

Dependent Claim 11 words

The process of claim 60 wherein said air is heated air.

Claim 67

Dependent Claim 23 words

The process of claim 61 wherein said heated air is produced by combustion using an excess of the stoichiometric air needed for combustion.

Claim 68

Dependent Claim 81 words

The combustion of claim 1 wherein the wet bulb temperature of the flue gases from said melting furnace is in excess of about 130° F. (54° C.) and said flue gases, prior to being directed into said preconditioning chamber, are diluted with air to decrease the wet bulb temperature thereof and the height of said preconditioning bed is less than the adjusted imminent aggregate forming height corresponding to the wet bulb temperature of the flue gases directed into said preconditioning chamber.

Claim 69

Dependent Claim 11 words

The process of claim 63 wherein said air comprises heated air.

Claim 70

Dependent Claim 131 words

A glass manufacturing process comprising: forming a bed of free water containing hydrologically unstable glass batch agglomerates; heating said formed bed for a time sufficient to form a hydrologically stabilized bed; discharging agglomerates of said stabilized bed to a vertical bed containing generally downwardly flowing agglomerates; heating the agglomerates in said vertical bed; conveying heated pellets from said vertical bed to a combustion fired glass melter for melting; said agglomerates of said vertical bed being heated by passing flue gases from said melter directly through said vertical bed; and said heating of said formed bed being done by passing a gaseous heating medium directly through said bed, said gaseous heating medium being an admixture of flue gases, after they have passed substantially through said vertical bed, with heated or ambient air.

Claim 71

Dependent Claim 131 words

A glass manufacturing process comprising: forming a bed of free water containing hydrologically unstable glass batch agglomerates; heating said formed bed for a time sufficient to form a hydrologically stabilized bed; discharging agglomerates of said stabilized bed to a vertical bed containing generally downwardly flowing agglomerates; heating the agglomerates in said vertical bed; conveying heated pellets from said vertical bed to a combustion fired glass melter for melting; said agglomerates of said vertical bed being heated by passing flue gases from said melter directly through said vertical bed; and said heating of said formed bed being done by passing a gaseous heating medium directly through said bed, said gaseous heating medium being an admixture of flue gases, after they have passed substantially through said vertical bed, with heated or ambient air.

Claim 72

Dependent Claim 48 words

The process of claim 65 wherein the height of said formed bed is no greater than about the adjusted inherent aggregate forming height corresponding to the wet bulb temperature of said admixture and the bed is heated for a period of time to substantially totally dry said agglomerates.

Claim 73

Dependent Claim 48 words

The process of claim 65 wherein the height of said formed bed is no greater than about the adjusted inherent aggregate forming height corresponding to the wet bulb temperature of said admixture and wherein said agglomerates are heated for a period of time to partially dry said agglomerates.

Claim 74

Dependent Claim 46 words

The process of claim 67 wherein said agglomerates have a non-linear strength drying curve with a minimum strength value at a predeterminable water content and wherein said agglomerates are heated for a sufficient period of time to have a water content less than said water content.

Claim 75

Dependent Claim 55 words

The process of claim 65 wherein the height of said formed bed is greater than the adjusted inherent aggregate forming height corresponding to the wet bulb temperature of said admixture and wherein said agglomerates are heated for a period of time sufficient to partially dry said agglomerates but insufficient to substantially totally dry said agglomerates.

Annuity Stage	Window Opens	Payment Deadline	Surcharge Period Until	Estimated Fee	Status
3.5 Years (Year 4)	1984-02-03	1984-08-04	1985-02-03	$2000.00	Window Closed / Lapsed
7.5 Years (Year 8)	1988-02-03	1988-08-04	1989-02-03	$3760.00	Window Closed / Lapsed
11.5 Years (Year 12)	1992-02-03	1992-08-04	1993-02-03	$7700.00	Window Closed / Lapsed

Pollution abating, energy conserving glass manufacturing process

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