Submerged combustion melters and methods of feeding particulate material into such melters

Abstract

Methods of melting particulate feedstocks in a submerged combustion melter employing an arrangement of one or more submerged combustion burners emitting combustion products into turbulent molten material. Operating the burners such that there is established a turbulent melting region extending vertically from the floor to a splash region, the splash region extending vertically between the turbulent melting region and a head space region, the head space region extending vertically between the splash region and the melter ceiling, the ceiling positioned above the floor a height H2. Feeding the particulate feedstock into the splash region through one or more inlet ports, the inlet ports positioned at a height H1 measured from the floor, where H1/H2 ranges from about 0.33 to about 0.67. The SCM may have a baffle extending from the ceiling into the splash region. A particulate feedstock conduit may be employed, having an exit port in the splash region.

What is claimed is: 
     
         1 . A method of melting particulate feedstocks in a submerged combustion melter (SCM) employing an arrangement of one or more submerged combustion (SC) burners emitting combustion products into turbulent molten material, 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, the ceiling positioned above the floor a height H2, the method comprising:
 (a) operating the SC burners such that there is established a turbulent melting region extending vertically from the floor to a splash region, the splash region extending vertically between the turbulent melting region and a head space region, the head space region extending vertically between the splash region and the melter ceiling;   (b) feeding the particulate feedstock into the splash region through one or more inlet ports, the inlet ports positioned at a height H1 measured from the floor, where H1/H2 ranges from about 0.33 to about 0.67; and   (c) melting the particulate feedstock in the SCM.   
     
     
         2 . The method in accordance with  claim 1  further comprising
 providing a baffle extending vertically downward from a ceiling of the SCM into the splash region and perpendicular to the SCM centerline, the baffle having a width equal to the width (W) of the SCM, the baffle positioned between the SCM feed end and the midpoint (M) of the SCM, and 
 operating the SCM so that the splash region submerges a distal end of the baffle, and allowing exhaust to flow out of an exhaust stack of the SCM attached to a ceiling of the SCM along the SCM centerline, the exhaust stack positioned between the midpoint (M) and the exit end wall of the SCM. 
 
     
     
         3 . The method in accordance with  claim 1  wherein
 the feeding at least a portion of the particulate feedstock into a splash region of the SCM comprises deploying one or more feed conduits having an inlet in the ceiling and an outlet in the splash region, 
 feeding the portion of the particulate feedstock though the one or more feed conduits, the one or more feed conduits positioned between the SCM feed end and the SCM midpoint (M), 
 providing a baffle extending vertically downward from a ceiling of the SCM into the splash region and perpendicular to the SCM centerline, the baffle having a width equal to the width (W) of the SCM, the baffle positioned between the one or ore feed conduits and the SCM midpoint (M), and 
 operating the SCM so that the splash region submerges the feed inlet conduit exit ends and a distal end of the baffle, and 
 allowing exhaust to flow out of an exhaust stack of the SCM attached to a ceiling of the SCM along the SCM centerline, the exhaust stack positioned between the midpoint (M) and the exit end wall of the SCM. 
 
     
     
         4 . A method of melting particulate feedstocks in a submerged combustion melter (SCM) employing an arrangement of one or more submerged combustion (SC) burners emitting combustion products into turbulent molten material, 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, the ceiling positioned above the floor a height H2, the method comprising:
 (a) operating the SC burners such that there is established a turbulent melting region extending vertically from the floor to a splash region, the splash region extending vertically between the turbulent melting region and a head space region, the head space region extending vertically between the splash region and the melter ceiling;   (b) feeding the particulate feedstock into the splash region through a single feedstock inlet port in a feed end of the SCM positioned along the SCM centerline, the inlet port positioned at a height H1 measured from the floor, where H1/H2 ranges from about 0.33 to about 0.67; and   (c) melting the particulate feedstock in the SCM.   
     
     
         5 . 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, the ceiling positioned above the floor a height H1, the SCM comprising:
 (a) one or more particulate feedstock inlet ports, the inlet ports positioned at a height H2, where H2/H1 ranges from about 0.33 to about 0.67.   
     
     
         6 . 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, the ceiling positioned above the floor a height H1, the SCM comprising:
 (a) a single particulate feedstock inlet port in a feed end of the SCM positioned along the SCM centerline, the inlet port positioned at a height H2 measured form the SCM floor, where H2/H1 ranges from about 0.33 to about 0.67.   
     
     
         7 . 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, the ceiling positioned above the floor a height H1, the SCM comprising:
 (a) a single particulate feedstock inlet port in a feed end of the SCM positioned along the SCM centerline, the inlet port positioned at a height H2 measured form the SCM floor, where H2/H1 ranges from about 0.33 to about 0.67; and   (b) a baffle extending vertically downward from a ceiling of the SCM into the splash region and perpendicular to the SCM centerline, the baffle having a width equal to the width (W) of the SCM, the baffle positioned between the SCM feed end and the midpoint (M) of the SCM, an exhaust stack of the SCM attached to a ceiling of the SCM along the SCM centerline, the exhaust stack positioned between the midpoint and the exit end wall of the SCM.   
     
     
         8 . 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, the ceiling positioned above the floor a height H1, the SCM comprising:
 (a) one or more feed conduits having an inlet in the ceiling of the SCM and an exit positioned at a height H2 measured from the floor, where H2/H1 ranges from about 0.33 to about 0.67, the one or more feed conduit inlets positioned between the SCM feed end and the SCM midpoint;   (b) a baffle extending vertically downward from a ceiling of the SCM into the splash region and perpendicular to the SCM centerline, the baffle having a width equal to the width (W) of the SCM, the baffle positioned between the one or more feed conduits and the midpoint of the SCM,   (c) an exhaust stack attached to a ceiling of the SCM along the SCM centerline, the exhaust stack positioned between the midpoint (M) and the exit end wall of the SCM.