Glass melting system based on induction heating integration and process thereof

Abstract

The application discloses a glass melting system based on induction heating integration and a process thereof, and belongs to the technical field of glass manufacturing. The system comprises a feeding preheating section and a melting homogenizing and refining section which are vertically arranged and integrally connected. The feeding preheating section comprises a feeding hopper and a medium-frequency preheating coil; the melting homogenizing and refining section comprises a noble metal melter, a melter medium-frequency coil surrounding the noble metal melter, an exhaust port, a working gas feeding port and a glass discharging port. The process is as follows: after preliminary preheating by the medium-frequency preheating coil, the mixture falls into the noble metal melter, is melted by the melter medium-frequency coil, and at the same time, the protective gas is introduced from the bottom to promote the refining and homogenizing, and finally the glass liquid flows out of the discharging port. The application solves the problems of the traditional kiln, such as large volume, short service life, high energy consumption, low control precision and poor safety, and has the advantages of compact structure, recyclable assets, low energy consumption, accurate temperature control, long service life, good safety and flexible production.

Description

Technical Field

[0001] This invention relates to the field of glass manufacturing technology, and in particular to a glass melting system and process based on integrated induction heating. Background Technology

[0002] In the glass manufacturing industry, large-scale production has long relied on traditional regenerative or heat exchange flame furnaces. This technology system uses specific refractory materials to build a large and complex furnace body, and is equipped with auxiliary facilities such as regenerators, reversing systems, and flues. It provides the heat energy required for melting by burning natural gas or using resistance heating. Despite its mature development and widespread application, this technology's inherent drawbacks are becoming increasingly apparent: First, the kiln structure is extremely complex and massive, resulting in huge initial infrastructure investment and a large land area required. Second, refractory materials are easily damaged under the continuous chemical erosion and intense thermal stress of high-temperature molten glass, making the kiln's service life typically limited. Upon reaching its expiration date, the kiln must be shut down for cold repairs, affecting production continuity and generating a large amount of waste refractory materials, leading to asset depletion and a severe environmental burden. Third, its thermal efficiency is relatively low, with a large amount of heat energy being discharged with high-temperature exhaust gases and dissipated through the kiln body, resulting in persistently high operating energy consumption. Furthermore, the flame heating method easily causes uneven temperature distribution within the kiln, and the temperature fluctuations caused by periodic reversal operations are detrimental to obtaining molten glass with excellent chemical and thermal uniformity, affecting the final product quality. Additionally, there is a potential safety risk of high-temperature molten glass leakage due to refractory material melting through. Finally, the design and operation mode of this type of kiln makes product formula switching difficult and startup and heating slow, making it difficult to adapt to the flexible production needs of modern manufacturing for multi-variety, small-batch, high-value-added glass products. In recent years, although technologies such as all-electric furnaces and oxy-fuel combustion have emerged to improve environmental protection and energy efficiency, they still rely heavily on refractory linings and have not fundamentally solved the problems of complex kiln structures and ineffective asset recovery. Therefore, developing a new type of glass melting technology and equipment that is compact, long-lasting, precisely controlled, safe, and flexible has become a key issue that the industry urgently needs to address. Summary of the Invention

[0003] The purpose of this invention is to provide a glass melting system and process based on integrated induction heating. This system aims to solve the technical problems of traditional glass furnaces, such as large size, short service life, unrecoverable assets, high energy consumption, low temperature control accuracy, and the safety hazard of material leakage, so as to achieve high efficiency, precision, safety and flexibility in the glass melting process.

[0004] This invention is achieved using the following technical solution: a glass melting system based on integrated induction heating, characterized in that it includes a vertically arranged and integrated feeding preheating section and a melting homogenization and clarification section; the feeding preheating section includes: a feeding hopper, located at the top of the system, for storing and supplying glass batch materials; a medium-frequency preheating coil, surrounding the vertical feeding channel below the feeding hopper, for preheating the falling batch materials; the melting homogenization and clarification section includes: a precious metal melter, located directly below the feeding preheating section, its top communicating with the feeding channel, for holding and melting glass materials; an exhaust port, located at the top of the precious metal melter, for discharging gases generated during the melting process; a melter medium-frequency coil, surrounding the precious metal melter, for heating the precious metal melter through induction heating; a working gas inlet, located at the bottom or lower side wall of the precious metal melter, for introducing gas into the melter; and a glass outlet, located at the bottom of the side wall of the precious metal melter, for discharging clarified molten glass.

[0005] Furthermore, the precious metal feeder is cylindrical or tapered at the bottom and is made of platinum, molybdenum, tungsten or their high-temperature alloys.

[0006] Furthermore, the gas introduced into the working gas inlet is an inert protective gas or a specific gas used to regulate the molten atmosphere.

[0007] Furthermore, the gas introduced through the working gas inlet forms an upward flow within the precious metal feeder.

[0008] Furthermore, the molten glass flowing out of the glass outlet is driven by the static pressure within the precious metal feeder.

[0009] A glass melting process using the glass melting system as described in any one of claims 1-5, characterized by comprising the following steps: S1. The glass batch material is added from the feed hopper and falls under the action of gravity through the feed channel surrounded by the medium frequency preheating coil, where it is preheated and dried. S2. The preheated batch material falls into the precious metal melter. The intermediate frequency coil of the melter works and heats the wall of the precious metal melter through induction heating, melting the batch material inside into molten glass. The gas generated by melting is discharged from the exhaust port. S3. Gas is introduced from the working gas inlet. The gas flows from bottom to top in the glass melt of the precious metal chemist, promoting the clarification and homogenization of the glass melt and forming a protective atmosphere on the inner wall of the chemist. S4. The melted, clarified and homogenized glass flows out from the glass outlet.

[0010] Furthermore, by controlling the input power of the intermediate frequency coil of the chemical reactor, precise control of the temperature of the molten glass inside the precious metal chemical reactor can be achieved.

[0011] The glass melting system and process based on integrated induction heating described in this invention have the following advantages: Adopting an integrated vertical design, the bulky refractory brick structure and heat storage system are completely eliminated, significantly reducing the size of the equipment. The core melting vessel is made of high-value metals such as platinum, molybdenum, and tungsten, or their alloys. After the equipment is decommissioned, the materials can be efficiently recycled and reused, resulting in a high asset value retention rate and avoiding the problem of traditional kilns ultimately becoming waste slag.

[0012] Using medium-frequency induction heating, heat is generated directly inside the metal furnace wall and conducted to the glass material, resulting in low heat loss and no high-temperature exhaust emissions. The overall thermal efficiency far exceeds that of traditional flame furnaces, significantly reducing energy consumption and carbon dioxide emissions.

[0013] Medium-frequency heating offers rapid response, and precise, stable temperature control can be achieved by adjusting the power. Combined with a sealed precious metal feeder, the glass melt is heated uniformly with minimal contamination, making it particularly suitable for producing high-uniformity, high-purity products such as optical glass and specialty glass.

[0014] The materials selected for the chemical feeder have high melting points and excellent creep and corrosion resistance at glass melting temperatures, resulting in a service life far exceeding that of traditional refractory materials. The all-metal sealed structure fundamentally eliminates the risk of leakage caused by refractory material melting through, ensuring safer operation.

[0015] The device starts and stops quickly, is easy to clean and change glass types, making it ideal for the research and development and production of a wide variety of small-batch, high-value-added glass products. Attached Figure Description

[0016] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. The drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on the structures shown in these drawings without creative effort.

[0017] Figure 1 This is a schematic diagram of the structure of the present invention; In the diagram, 1-feed hopper, 2-medium frequency preheating coil, 3-precious metal feeder, 4-exhaust port, 5-feeder medium frequency coil, 6-working gas inlet, 7-glass outlet. Detailed Implementation

[0018] To make the objectives, technical solutions, and advantages of the embodiments of the present invention clearer, the technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. The components of the embodiments of the present invention described and shown in the accompanying drawings can generally be arranged and designed in various different configurations.

[0019] Therefore, the following detailed description of the embodiments of the invention provided in the accompanying drawings is not intended to limit the scope of the claimed invention, but merely to illustrate selected embodiments of the invention. All other embodiments obtained by those skilled in the art based on the embodiments of the invention without inventive effort are within the scope of protection of the invention. Example

[0020] like Figure 1 As shown, this embodiment provides a glass melting system based on integrated induction heating, mainly composed of a feeding preheating section and a melting homogenization and clarification section, which are arranged vertically and connected in one piece. Specifically, the system includes a feeding hopper 1, a medium-frequency preheating coil 2, a precious metal melter 3, an exhaust port 4, a melter medium-frequency coil 5, a working gas inlet 6, and a glass outlet 7.

[0021] The feed hopper 1 is located at the top of the system and is used to store and continuously supply glass batch materials. The bottom outlet of the feed hopper 1 is connected to a vertical feed channel.

[0022] The medium-frequency preheating coil 2 is tightly wrapped around the vertical feeding channel below the feeding hopper 1. Its function is to use the principle of medium-frequency electromagnetic induction to preheat and dry the glass batch material falling from the feeding hopper 1 through the channel, so as to remove some moisture.

[0023] The precious metal melter 3, serving as the core melting and clarification vessel, is located directly below the feed preheating section. Its top is connected to the bottom of the feed channel above via a constricted or straight channel to receive the preheated batch material. The melter 3 is entirely made of platinum, molybdenum, tungsten, or their high-temperature alloys, and its shape is preferably cylindrical or tapered at the bottom, directly containing and melting the glass batch material.

[0024] The exhaust port 4 is located at the top of the precious metal feeder 3 and is connected to the internal cavity of the feeder 3. It is used to discharge volatile gases such as water vapor and carbon dioxide generated during the heating, decomposition and melting of the batch material.

[0025] The intermediate frequency coil 5 of the glass mixer is tightly wrapped around the periphery of the precious metal glass mixer 3. The coil 5 is powered by an intermediate frequency power supply. When it is working, the intermediate frequency alternating electromagnetic field generated directly produces a strong eddy current in the metal wall of the precious metal glass mixer 3, thereby causing the glass mixer 3 to heat up rapidly and efficiently and evenly conduct the heat to the glass batch material contained inside, so that it can complete the melting, clarification and homogenization process.

[0026] The working gas inlet 6 is located at the bottom of the system, specifically at the lower part of the side wall of the precious metal carburizer 3 or at the bottom of the L-shaped flow structure. This inlet 6 is used to introduce an inert protective gas or a specific gas for adjusting the molten atmosphere. The introduced gas flows upwards inside the precious metal carburizer 3, forming a protective atmosphere to prevent oxidation of the carburizer 3 material at high temperatures. Furthermore, the rising bubbles help remove residual gas from the melt and promote chemical homogenization of the molten glass.

[0027] The glass outlet 7 is located at the bottom of the side wall of the precious metal feeder 3 and is connected to the molten glass inside the feeder 3. After being fully melted, homogenized and clarified, the high-quality molten glass can flow out continuously or intermittently from this outlet 7 under hydrostatic pressure and enter the subsequent forming, casting or drawing processes.

[0028] The working principle of this embodiment is as follows: The glass batch material is first continuously fed from the top feed hopper 1 and falls through the vertical feed channel under gravity. During the fall, the material passes through the section surrounded by the medium-frequency preheating coil 2. The medium-frequency electromagnetic field generated by the coil 2 causes the batch material itself or the channel wall to generate heat, thus preheating and drying the material and removing physical water and some crystal water.

[0029] The preheated batch material then falls through a channel into the precious metal melter 3 below. The intermediate frequency coil 5 of the melter operates, generating eddy currents within the metal wall of the precious metal melter 3, rapidly heating it to the high temperature required for glass melting. The batch material falling into the melter 3 quickly melts to form molten glass. A large amount of gas generated during the melting process is discharged through the exhaust port 4 at the top.

[0030] Meanwhile, the protective gas introduced from the bottom working gas inlet 6 forms an upward flow of bubbles in the molten glass. This protective atmosphere is crucial for crystallizers made of easily oxidized metals such as molybdenum and tungsten, effectively preventing the crystallizer from being oxidized and corroded at high temperatures.

[0031] Finally, the high-quality molten glass, after thorough melting, clarification, and homogenization, accumulates in the conditioner 3. When the liquid level reaches a certain height, the molten glass flows out from the glass outlet 7 on the side under hydrostatic pressure, and can be directly fed to the forming equipment. By precisely controlling the power of the intermediate frequency coil 5, the temperature of the molten glass in the conditioner 3 can be precisely controlled. The entire system has a compact structure, realizing integrated continuous operation from feeding, preheating, melting to clarification and homogenization.

[0032] The above embodiments describe the basic principles, main features, and advantages of the present invention. Those skilled in the art should understand that the present invention is not limited to the above embodiments. The embodiments and descriptions in the specification are merely illustrative of the principles of the invention. Modifications and variations made by those skilled in the art without departing from the spirit and scope of the invention should be within the protection scope of the appended claims.

Claims

1. A glass melting system based on integrated induction heating, characterized in that, The system includes a vertically arranged and integrated feeding preheating section and a melting homogenization and clarification section; the feeding preheating section includes: a feeding hopper (1), located at the top of the system, for storing and supplying glass batch materials; a medium-frequency preheating coil (2), surrounding the vertical feeding channel below the feeding hopper (1), for preheating the falling batch materials; the melting homogenization and clarification section includes: a precious metal feeder (3), located directly below the feeding preheating section, with its top connected to the feeding channel, for holding and melting glass materials; and an exhaust port. (4) is located at the top of the precious metal melter (3) and is used to discharge the gas generated during the melting process; the intermediate frequency coil (5) of the melter is surrounded around the precious metal melter (3) and is used to heat the precious metal melter (3) through induction heating; the working gas inlet (6) is located at the bottom or lower part of the side wall of the precious metal melter (3) and is used to introduce gas into the melter; the glass outlet (7) is located at the bottom of the side wall of the precious metal melter (3) and is used to discharge the clarified glass liquid.

2. The glass melting system based on integrated induction heating according to claim 1, characterized in that, The precious metal feeder (3) is a cylindrical container or a container with a tapered bottom, and is made of platinum, molybdenum, tungsten or their high-temperature resistant alloys.

3. The glass melting system based on integrated induction heating according to claim 1, characterized in that, The gas introduced into the working gas inlet (6) is an inert protective gas or a specific gas used to regulate the molten atmosphere.

4. The glass melting system based on integrated induction heating according to claim 1, characterized in that, The gas introduced from the working gas inlet (6) forms an upward flow within the precious metal feeder (3).

5. The glass melting system based on integrated induction heating according to claim 1, characterized in that, The molten glass flowing out of the glass outlet (7) is driven by the static pressure inside the precious metal feeder (3).

6. The glass melting system based on integrated induction heating according to claim 1, characterized in that, The medium-frequency preheating coil (2) causes the wall of the vertical feed channel or the glass batch to be heated by the medium-frequency electromagnetic field, so as to remove physical water and some crystal water in the glass batch.

7. A glass melting process using the glass melting system as described in any one of claims 1-6, characterized in that, Includes the following steps: S1. The glass batch material is added from the feed hopper (1) and falls under the action of gravity through the feed channel surrounded by the medium frequency preheating coil (2), where it is preheated and dried. S2. The preheated batch material falls into the precious metal feeder (3). The intermediate frequency coil (5) of the feeder works and heats up the wall of the precious metal feeder (3) through induction heating, melting the batch material inside into glass liquid. The gas generated by melting is discharged from the exhaust port (4). S3. Gas is introduced from the working gas inlet (6). The gas flows from bottom to top in the glass melt of the precious metal chemicalizer (3), promoting the clarification and homogenization of the glass melt and forming a protective atmosphere on the inner wall of the chemicalizer. S4. The melted, clarified and homogenized glass flows out from the glass outlet (7).

8. The glass melting process according to claim 7, characterized in that, By controlling the input power of the intermediate frequency coil (5) of the chemical feeder, the temperature of the molten glass inside the precious metal chemical feeder (3) can be precisely controlled.

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