Melting furnace and method of use
TECHNICAL FIELD 
     This invention relates to a process and apparatus for reducing the particulate emissions in the exhaust gas from a glass melting furnace. 
     BACKGROUND ART 
     Methods are known in the art of glass manufacturing for preheating glass batch wherein glass-forming, batch ingredients are brought in direct contact with heated media within a chamber. The particulate or granular glass batch raw materials are brought in particle-particle heat exchange with media that has been heated with an external burner or heated with exhaust gases from a glass melting furnace. This method allows the exchange of large quantities of heat economically and uniformly. 
     The preheating of glass batch at times may generate high particulate emissions in the chamber. Often there also are particulate emissions in the flue gases exhausting from the glass melting furnace. 
     U.S. Pat. Nos. 4,338,112, 4,338,113 and 4,362,543 disclose processes which improved on known means for reducing the particulate emissions in the exhaust gas stream from a glass melting furnace. Cool exhaust gases were electrically charged and passed through an electrified bed of agglomerates to remove particulate from the spent gases. 
     DISCLOSURE OF INVENTION 
     According to this invention, I have provided a single means for reducing the particulate emissions in the exhaust gas stream from a glass melting furnace and for preheating of glass batch particulate to be charged to the furnace. Ionization of a particulate laden off gas stream from an industrial process is difficult if not impossible above temperatures of 1000° F. to 1200° F. It is the normal practice to cool the gas stream with an external means which usually consumes heat and lowers efficiency. My invention lowers the gas stream temperature by first subjecting it to a mass of pellets or other heat absorbing medium to extract heat. After that step reduces the temperature to 1000° F., the gas stream is subjected to the ionizer and collection phase. The pellets then go through the process and heat is conserved. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     FIG. 1 shows a side view of the preferred apparatus of this invention. 
     FIG. 2 shows an alternative embodiment of the apparatus of this invention. 
     FIG. 3 shows another embodiment of the apparatus of this invention. 
     FIG. 4 shows still another embodiment of this invention. 
    
    
     BEST MODE OF CARRYING OUT INVENTION 
     My invention includes durable heat transfer media formed of glass batch agglomerates, glass, ceramic, glass-ceramics, steel, stainless steel, aluminum, gravel or the like. 
     In FIG. 1, heat transfer media may be heated with flue gases at a temperature normally ranging up to 1600° F. (872° C.) from a glass melting furnace. 
     In vessel 10, dirty exhaust gases are fed through internal conduit 11. Conduit 11 extends any suitable depth into vessel 10 and preferably terminates in truncated cone 12 having an opening 13 in the lower end of vessel 10. The dirty exhaust gases flow down conduit 11 and under cone 12 to an area where heat is absorbed by a mass of media to lower gas temperatures to about 1000° F. (538° C.) The cooled exhaust gases flow past ionizer 14 where particulate in the exhaust gases is negatively charged. The negatively charged gases then flow through louvers 15 to positively charged area 16. Negatively charged particulate collects on positively charged media in area 16. The clean gas then flows to the atmosphere via conduit 17. 
     The media enters vessel 10 through grids 18 which places a positive charge on the media. Negatively charged particulate collects on the positively charged media, and the resulting coated media then flows through restricted area 19. Area 19 restricts the passage of media sufficiently to cause the flow of gases through ionizer 14 rather than area 19. The media densely packs area 19 so that the gases take the path of least resistance through ionizer 14. Media exits vessel 10 through opening 20. 
     A blower or fan (not shown) may pull clean exhaust gases from vessel 10. 
     FIG. 2 shows another embodiment where restriction 19 is more centrally located than in FIG. 1. 
     FIG. 3 shows another embodiment where restriction 19 is located in the innermost portion of unit 10. 
     FIG. 4 shows the solids from unit 10 being fed to rotary drum 34 to preheat batch for feeding to a melting furnace (not shown). 
     Preferably, the solids, e.g., media or agglomerates, are electrically charged and the particulate in the gas stream is given an electrical charge of an opposite polarity. The charged solids then act as collection sites for the oppositely charged particulate in the exhaust gases. 
     In another embodiment, a suitable electrical charge is also provided. Particulate entrained in the exhaust gas is electrically charged. An electric field is then employed to polarize the solids or media in the upper region of the chamber. The electric field produces caps of positive and negative charges on each solid. The charge caps then act as collection sites for previously charged particulate in the exhaust gases. 
     INDUSTRIAL APPLICABILITY 
     Generally, this invention is employed in a glass melting furnace from which molten glass issues. A shaft type vessel 10 maintains a vertical bed of agglomerates, with vessel 10 preferably containing an upper substantially cylindrical portion and a lower inverted frustoconical portion. Hot exhaust gases are conveyed to a lower portion of vessel 10 and passed countercurrently to the gravitationally downwardly flow of the agglomerates therein so as to preheat the agglomerates to an elevated temperature. The agglomerates, in turn, remove any particulate from the furnace exhaust gas. The heated agglomerates are discharged from the lower portion of the preheater and, without significant cooling, are directly transmitted to a glass melting furnace. 
     In another embodiment, the media may be heat transfer media rather than agglomerates of glass batch. 
     In operation, the media of vessel 10 become coated with collected particulate. When the desired amount of coating and temperature level has taken place, the bed media is removed, and recycled media is introduced continuously. The coated media is removed to heat exchange drum 34 where the particulate is removed from the media and the batch is heated. The media is recycled back to vessel 10 for reuse. The particulate, which generally is glass batch, is collected and charged with the preheated batch directly to a glass melting furnace. 
     The cylindrical drum 34 shown in FIG. 4 typically is inclined at an angle. In the preferred embodiment, the batch charging end of the container is elevated above the media charging end. While the angle can vary widely, generally the drum will form an acute angle with a horizontal line no greater than about 45° and typically less than 15°. Preferably, the angle is less than 5°. 
     In order to bring the batch in direct contact with the hot media, an arrangement of baffles is attached to the interior of the container. These baffles are 2 to 3  inches wide. These baffles usually are bolted to the walls of the drum and extend the length of the drum. All of the baffles in combination with the rotation of the drum aid in tumbling the media and batch in direct contact with each other. Typically, cold batch is fed with a screw feeder (not shown) that extends into the interior of the drum. This extension into the drum aids in reducing the amount of batch that may leave the drum with media. In one embodiment, hot media also is fed with a screw feeder (not shown) that extends into the interior of the drum. 
     While the tumbling of the media and batch occurs through agitation from the baffles and rotation of drum, movement of the batch and media through the drum is believed to occur in the following manner. The media and batch form gradients in the drum and generally flow downhill in a direction along the gradients and in opposite directions. The batch and media tumble and move over each other as they flow from the high end to the low end of the pile of material in the container. 
     An embodiment for removing media from the drum comprises an expanded metal scroll (not shown) that contains over 70% openings or voids. Hole size in the scroll is important as the holes must be big enough to allow batch to fall through. Typically, the holes are similar to a diamond in shape and are 1 inch by 3/4 inch in size. As the scroll rotates, the media moves along a spiral path from the cylindrical wall region of the drum to the media exit, which is generally the midregion or center of the drum. The scroll is attached to the drum and rotates with the drum causing the media to move along a spiral path through the scroll to the center of the scroll. The batch falls through the voids of the scroll back into the interior of the drum without being discharged with the media. The screw feeder usually extends past the scroll discharge so that batch will not be charged onto the scroll. 
     It is while the tumbling of the hot media and batch occurs that the particulate coating on the media from vessel 10 becomes mixed with the batch being heated in cylindrical drum 24. Movement of the media through the scroll also strips the coated particles from the media. The combined glass batch is heated in the drum and then charged to the glass melting furnace.