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Petroleum Coke Powder Fired Glass Furnace

What is Petrol coke?
As well-known, at the present the energy saving for glass industry is a critical problem that makes up the glass industry’s success or failure.
The petrol coke is residuum after petroleum refining industry, i.e. crude oil is separated by CDU(Crude Distillation Unit) into light/heavy oil, the heavy oil is treated by thermal cracking unit, and then the last residuum is Petroleum Coke. The coke are black blocks or particles in different sizes and shapes contained with Carbon of 90~97% in weight and H of 1.5-8% as well as N, S, Cl, heavy metal compounds. Usually it contains also ash (5% or more) and volatile (11% around). The petrol coke can be for many usages, one of them is acted as fuel for industry furnaces or ovens. The price of petrol coke is much cheaper than heavy oil or natural gas, and that does not make any contamination to glass in the furnace.

Why can we use Petrol coke for glass furnace

1.The comparison of calories between petrol coke and heavy oil:

Petrol coke: 8500~8600 Kcal/kg
Heavy oil: 9500~9600 Kcal/kg.
Therefore 1.05~1.10 tons of petrol coke can substitute 1 ton of heavy oil, and experiment proves that the flame temperature of petrol coke powder fired can be stably at 1670~1710℃， which definitely meets the requirement of general glass furnace.

2.Petrol coke advantages in combustion against heavy oil
●flame properties of petrol coke: The length, the cover area and the shape are similar as heavy oil flame or even better than heavy oil flame.
Particularly the temperature of petrol coke flame at the port is lower than that of heavy oil. This feature reduces the risk of burning out to the furnace crown bottom close to the port.

● For the water produced during combustion of petrol coke powder, after
comparison, the water amount produced by petrol coke burning is less than that of heavy oil’s.
● The combustion air required by petrol coke powder is similar as that of heavy oil, the exhaust gas for both cases are also same.

How to use petrol coke as a fuel for glass furnace

1.For easy combustion, transporting and spraying into glass furnace the petrol coke has to be grinded into powder with 200 meshes or finer.

2.The petrol coke must be crushed and dried, then fine-grinded in the petrol coke powder supplier’s plant. The moisture of petrol coke powder should be kept at ≤5%.

3.The specification of petrol coke powder for glass furnace:
Fixed Carbon C≥90; Sulphur S≤1.3%; Ash 0-1%, volatile matters≤1.5%

Calorie 8000~8600
The 1.10~1.17 tons petrol coke’s calorie=1.00 tons heavy oil’s calorie. This is the calculation base when costs of heavy oil and petrol coke are compared.

4.The package equipment for petrol coke powder combustion system

Special package equipment for petrol coke applied in glass furnace was
developed, which includes petrol coke powder storage, powder-air mixing and conveying system, powder spraying burner and reversal unit for either side-port glass furnace or end-port furnace. These are quite different from normal pneumatic conveying (air-conveying) system. This complete system must enable powder flow to be controlled by means of very good fluidization in the system, which is stable, homogeneous in flow rate, powder density and pressure. The spraying coke powder must be mixed with combustion air in adequate concentration. The sprayed flame must be adjustable in length and powder concentration to keep stable combustion, also to maintain the flame in good rigidity and brightness. The system must guarantee a high rate of burning off(99%) and no interrupt of flame. Once an adjustment of the flame has been done, the furnace temperature and flame distribution must maintain consistent for a period.
All of the a.m. performances can not realized by normal pneumatic conveying system.

What the petrol coke powder combustion system looks like

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Fig.1 Storage silos of petrol coke powder and coke powder feeding system

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Fig.2 Continuous powder conveying pump unit

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Fig.3 Coke powder and combustion air mixing and conveying pump units by the furnace

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Fig. 4 Petrol coke powder spraying burner at the port of glass furnace

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Fig.5 Control and monitoring system in control room

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Fig.6 Control and monitoring system

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Fig.7 Glass furnace using petrol coke powder
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Fig.8 Outside storage silo of a glass plant

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Fig.9 One of stack with white smoke shows petrol coke burning off that is much better than heavy oil fired glass furnace to the environment protection. Our customer’s burning off rate reaches 99%.

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Fig.10 Diagram of petrol coke powder conveying system for a pair of
ports of glass furnace.

What is the economic efficiency by petrol coke

Due to price difference between heavy oil or natural gas and petrol coke the glass companies, who used petrol coke fuel, shall definitely get a big payback and good profit annually.

For example, a 400T/D float glass furnace needs 70 tons of heavy oil. If the fuel of the furnace is substituted by petrol coke powder, the furnace needs 1.17x70=82 tons of petrol coke powder. According to the current price of heavy oil and petrol coke powder, the benefit per month created by the fuel cost saving could be USD 300,000~400,000. The investment of petrol coke powder system could be returned in 1-2 months. Therefore the payback is very high. After that short time the benefit shall be a big part of profit for the company.

We have another customer report, which said they saved fuel cost about US$ 6.5 million yearly by petrol coke powder to substitute heavy oil for their 500 T/D float glass furnace.

Obviously, the benefit by using petrol coke powder for glass industry is notable, realizable and believable.

What we can do for you

We supply design, manufacturing and engineering to our customer for petrol coke substitution machines and engineering on base of turn-key contract, no matter what is reforming engineering of existing furnace or completely new furnace. Sincerely welcome inquiry and ordering from you. Whish you prosperous business.