Electric melting furnace for glass bead production

Abstract

The utility model discloses an electric melting furnace for producing glass beads, which comprises a supporting structure for supporting a furnace body; the furnace body internally comprises an inner cavity for accommodating molten glass; the inner cavity comprises at least one main molten pool and a clarification pool, the clarification pool is communicated with the main molten pool, and at least one discharge port is formed in the lower part of the inner cavity; the heating system comprises a heating element arranged above the main molten pool, a first electrode transversely inserted into the main molten pool, a second electrode vertically inserted into the clarification pool from the upper portion, at least one first temperature sensor arranged in the main molten pool and at least one second temperature sensor arranged in the clarification pool. The inner cavity of the furnace body is divided into the main molten pool and the clarification pool, the main molten pool is provided with the top heating element and the first electrode which is transversely inserted, the clarification pool is provided with the second electrode which is vertically inserted, and the temperature sensors are arranged in the two areas. The technical problems that glass batch melting is insufficient, bubbles are difficult to effectively discharge, and components and temperature are difficult to uniformly control are solved.

Description

Technical Field

[0001] This utility model relates to the field of glass melting equipment technology, and in particular to an electric melting furnace for producing glass beads. Background Technology

[0002] Glass beads, as a functional material, are widely used in road marking reflectors, industrial sandblasting, composite material filling, and decoration. The production of glass beads typically involves steps such as raw material mixing, high-temperature melting, shaping (e.g., water-quenched granulation followed by spheroidization or direct drop forming), and subsequent processing (e.g., screening and drying). Among these, glass melting is the key step that determines the final product quality and production cost.

[0003] Currently, glass melting mainly uses flame furnaces (using fuels such as natural gas and heavy oil) or electric furnaces. Although traditional flame furnaces are technically mature, they have the following problems in the melting process: 1) They consume a lot of energy, and the flue gas produced by combustion pollutes the environment, failing to meet increasingly stringent environmental protection requirements; 2) Direct contact with the flame may lead to uneven volatilization of glass components or the introduction of impurities; 3) The temperature distribution inside the furnace is not easy to control precisely, which may affect the homogenization quality of the glass.

[0004] To overcome the drawbacks of flame furnaces, electric melting technology has been introduced into the glass melting field. Electric melting furnaces utilize the Joule heat generated by the resistance of the molten glass itself (or heat transfer through heating elements) to melt the glass, offering advantages such as high thermal efficiency, low environmental pollution, and easy control over the quality of the molten glass. Electric melting furnaces have also been applied in glass bead production. However, existing electric melting furnaces or processes used for glass bead production may still have some technical problems, such as:

[0005] Glass has poor electrical conductivity in its solid state, and electric furnaces require preheating by an auxiliary heating system for cold start-up. How to efficiently and quickly complete the start-up and smoothly transition to main electrode heating, and how to further optimize energy utilization efficiency during the stable production stage, remain issues that need attention.

[0006] The design of electrode arrangement, power distribution, and furnace structure to ensure that raw materials are fully melted in the furnace and bubbles are effectively discharged (clarified) to obtain glass melt with uniform composition, suitable viscosity, and suitable for subsequent water quenching or forming directly affects the qualification rate and performance of the final glass bead products.

[0007] The discharge from the electric melting furnace needs to be effectively connected with the subsequent water quenching system to ensure that the molten glass can be smoothly and safely transformed into glass particles within the required particle size range. The stability and compatibility of the entire system need to be optimized.

[0008] Therefore, developing a more optimized electric furnace is of great practical significance in addressing the potential problems in the melting process of existing glass bead production processes, such as energy consumption, environmental protection, melting quality, and process matching. Summary of the Invention

[0009] The technical problem to be solved by this utility model is to address the technical issues existing in the cold start efficiency, energy utilization, melting and clarification effect, and precise temperature control of the existing electric melting furnace for glass bead production, and to provide an electric melting furnace for glass bead production that can achieve efficient melting, clarification and homogenization of glass batch materials and precise temperature regulation, thereby improving the energy efficiency and product quality of glass bead production.

[0010] The technical solution adopted by this utility model to solve its technical problem is:

[0011] An electric melting furnace for producing glass beads, comprising:

[0012] Support structure, used to support the furnace body;

[0013] The furnace body includes an inner cavity for containing molten glass; the inner cavity includes at least one main molten pool and a refining pool, the refining pool being connected to the main molten pool, and at least one discharge port being provided at the lower part of the inner cavity;

[0014] The heating system includes a heating element disposed above the main molten pool, a first electrode inserted laterally into the main molten pool, a second electrode inserted vertically from the top into the refining pool, at least one first temperature sensor disposed in the main molten pool, and at least one second temperature sensor disposed in the refining pool.

[0015] Preferably, the heating element disposed above the main molten pool is a silicon carbide rod.

[0016] Preferably, the discharge port includes a first discharge port located in the bottom area of ​​the main molten pool.

[0017] Preferably, the second electrode includes a pair of electrodes adapted to be vertically inserted into the clarification tank from above, and the second temperature sensor is disposed between the pair of electrodes.

[0018] Preferably, the discharge outlets include two second discharge outlets located in the bottom area of ​​the clarification tank.

[0019] Preferably, it further includes a control system for receiving temperature signals from a temperature sensor and adjusting the power supplied to the heating element, the first electrode, and the second electrode based on the temperature signals, so as to control the temperature in the main molten pool and the refining pool.

[0020] The technical effects that this utility model can achieve include the following:

[0021] By dividing the furnace cavity into a main melting pool and a refining pool, and equipping the main melting pool with a top heating element and a horizontally inserted first electrode, and equipping the refining pool with a vertically inserted second electrode from the top, and setting temperature sensors in both areas, a melting and refining system with clearly defined functional zones and independently controllable heating methods is formed. This effectively solves the technical problems of insufficient melting of glass batch materials, difficulty in effectively removing bubbles, and difficulty in uniformly controlling composition and temperature. It achieves efficient melting of glass melt, full refining and homogenization, and precise temperature control in key stages, ensuring that high-quality glass melt with uniform composition and suitable viscosity is obtained from the discharge port of the refining pool.

[0022] By simultaneously setting a top heating element and a side-wall immersed first electrode in the main molten pool, a composite heating system is formed, which solves the problems of poor conductivity and difficulty in cold start preheating of glass batch material in solid state, and facilitates efficient and rapid start-up; at the same time, combined with the immersion electrode to internally heat the melt, the energy utilization efficiency and melting rate in the stable production stage are improved, effectively solving the problems of difficult start-up and high energy consumption. Attached Figure Description

[0023] Figure 1 This is a schematic diagram of the structure of the electric melting furnace for glass bead production in Example 1.

[0024] Reference numerals in the attached drawings: 1. Steel frame; 2. Furnace body; 3. Main molten pool; 4. Refining pool; 5. Silicon carbide rod; 6. First electrode; 7. Second electrode; 8. First thermocouple; 9. Second thermocouple; 10. First discharge port; 11. Second discharge port. Detailed Implementation

[0025] The present invention will be further described below with reference to the accompanying drawings and embodiments, but these specific embodiments do not limit the scope of protection of the present invention in any way. Example

[0026] like Figure 1 As shown, an electric melting furnace for producing glass beads includes a steel frame 1, a furnace body 2, a main melting pool 3, a refining pool 4, silicon carbide rods 5, multiple first electrodes 6, second electrodes 7, a first thermocouple 8, a second thermocouple 9, and a first discharge port 10 and a second discharge port 11. The furnace body 2 is mounted and fixed on a steel frame 1, which provides a stable foundation support for the entire furnace body 2. The interior of the furnace body is constructed of refractory material, forming an inner cavity to contain molten glass.

[0027] In this embodiment, the inner cavity of the furnace body 2 is divided into at least two main functional areas: the main melting pool 3 and the refining pool 4. The main melting pool 3 is located on the left side of the center of the furnace body 2 and is the core area where the material undergoes the main melting reaction. Its main function is to receive the incoming material and transform it from a solid to a liquid state. The refining pool 4 is located on one side of the main melting pool 3 and is connected to the main melting pool 3 through bottom or side flow holes. It is used for clarifying, homogenizing or temperature adjustment of the molten material, as well as adjusting the viscosity and temperature of the glass melt to be suitable for subsequent processes.

[0028] In this embodiment, the upper space of the main molten pool 3 is provided with multiple silicon carbide rods 5, which are vertically suspended below the furnace top to provide heat as resistance heating elements. Simultaneously, multiple horizontally inserted first electrodes 6 are provided on the sidewall of the main molten pool 3. These first electrodes 6 are directly inserted into the molten material and heated by Joule heating. Additionally, a first thermocouple 8 is provided in the upper part of the main molten pool 3, near the silicon carbide rods 5, for monitoring the temperature of the main molten pool 3 region.

[0029] In this embodiment, a first discharge port 10 is provided at the bottom directly below the main molten pool 3, which is used to discharge the molten material in the main molten pool 3 or to perform an emptying operation.

[0030] In this embodiment, the heating inside the clarification tank 4 is mainly achieved by two second electrodes 7 inserted vertically from the top of the furnace. These two second electrodes 7 are also in direct contact with the molten material in this area. Between these two second electrodes 7, there is a second thermocouple 9 for monitoring the temperature of the clarification tank 4 area. Below the clarification tank 4, there are two second discharge ports 11 for taking out or discharging the molten material in this area.

[0031] This electric melting furnace employs a composite heating method (resistance heating of silicon carbide rod 5 and direct electric heating of electrodes) and has at least two functional zones (main melting pool 3 and refining pool 4). The main melting pool 3 undertakes the main melting task and is heated by the first electrode 6 on the side wall and the top silicon carbide rod 5; the refining pool 4 is heated by the second electrode 7 on the top and is used for subsequent processing. Each zone is equipped with independent temperature sensors (first thermocouple 8 and second thermocouple 9, respectively) and discharge ports (first discharge port 10 and second discharge port 11, respectively).

[0032] The working principle and method of the above-mentioned electric melting furnace for producing glass beads are as follows:

[0033] The first step, before adding the glass batch, is to preheat the electric furnace by starting its heating system. The control system supplies power to the silicon carbide rod 5 located above the main molten pool 3, the first electrode 6 inserted into the side wall of the main molten pool 3, and the second electrode 7 at the top of the refining pool 4. The silicon carbide rod 5 heats the furnace interior and refractory material through radiation, while the first and second electrodes 6 and 7 are prepared to directly heat the subsequently added glass batch. This stage aims to slowly and uniformly raise the furnace lining to the operating temperature required for glass melting, preventing damage to the refractory material due to thermal shock. The first thermocouple 8 and the second thermocouple 9 inside the furnace monitor the temperature in real time and provide feedback to the control system for precise control of the heating curve.

[0034] The second step involves adding the pre-mixed glass batch to the main molten pool 3 through the feeding port after the furnace reaches the set feeding temperature. Heating within the main molten pool 3 is a combined process: the silicon carbide rod 5 above continuously provides radiant heat to heat the surface of the material layer; simultaneously, the first electrode 6 inserted into the side wall is energized, utilizing the Joule heating effect generated by the current passing through the glass batch and the gradually forming glass melt to heat it from the inside. This heating method effectively transforms the solid glass batch into a high-temperature glass melt.

[0035] Third, as the glass batch in the main melting pool 3 continues to melt, the resulting glass melt, due to the agitation caused by gravity, temperature difference, and bubbles generated by chemical reaction, will gradually flow through the flow channels designed inside the furnace to the refining pool 4 area. This flow process helps the initial mixing of the glass melt.

[0036] The fourth step involves the glass melt entering the refining tank 4, where it continues to be heated and its temperature controlled by the second electrode 7, which is vertically inserted at the top of this area. This area is a critical refining stage in the glass melting process. Its main purposes include: maintaining a high and stable temperature and sufficient residence time to encourage residual microbubbles in the glass melt to rise and escape, thereby improving the transparency and quality of the glass; utilizing the thermal convection or possible electromagnetic stirring effect generated by the second electrode 7 to further promote the homogeneity of the glass melt composition and eliminate defects such as streaks and nodules; and precisely adjusting and stabilizing the glass melt at the specific viscosity and temperature required for the downstream glass bead forming process. The second thermocouple 9 in this area is used to accurately monitor and control the temperature during this stage.

[0037] Fifth, throughout the melting process, the first thermocouple 8 and the second thermocouple 9, distributed in the main melting pool 3 and the refining pool 4, continuously monitor the temperature of the glass melt in their respective areas and transmit the signals to the central control system of external equipment (not shown in the figure, a conventional technique). Based on the preset glass melting process curve and real-time temperature feedback, the control system automatically adjusts the power supplied to the silicon carbide rod 5, the first electrode 6, and the second electrode 7, achieving precise control of the glass melt temperature in different areas of the furnace, ensuring sufficient melting, good refining, thorough homogenization, and suitable temperature.

[0038] Step 6: When the glass melt in the refining tank 4 reaches the required quality and temperature to form glass liquid, it can be taken out stably, continuously or intermittently through the second discharge port 11 at the bottom and directly supplied to the subsequent glass bead forming equipment. The first discharge port 10 at the bottom of the main melting tank 3 is usually used to discharge the sediment generated during the melting process, to empty when changing glass types, or to discharge material under special circumstances.

[0039] Finally, when the production task is completed or maintenance is required, the furnace shall be shut down in accordance with the operating procedures of the glass melting furnace, the heating power shall be gradually reduced, and the molten glass in the furnace may be emptied. The first electrode 6, the second electrode 7, the silicon carbide rod 5, the refractory material, the first thermocouple 8, the second thermocouple 9 and the control system shall be inspected and maintained regularly.

[0040] The above description is merely a preferred embodiment of this utility model and is not intended to limit the scope of protection of this utility model. Any innovative improvements or substitutions based on this utility model should fall within the scope of the claims of this utility model. Furthermore, the parameters, materials, and processes mentioned in the above embodiments are not unique. Without departing from the technical essence of this utility model, those skilled in the art can make various alternative choices, and these alternative solutions should also be considered to fall within the scope of protection of this utility model.

Claims

1. An electric melting furnace for producing glass beads, characterized in that, include: Support structure, used to support the furnace body; The furnace body includes an inner cavity for containing molten glass; the inner cavity includes at least one main molten pool and a refining pool, the refining pool being connected to the main molten pool, and at least one discharge port being provided at the lower part of the inner cavity; The heating system includes a heating element disposed above the main molten pool, a first electrode inserted laterally into the main molten pool, a second electrode inserted vertically from above into the refining pool, at least one first temperature sensor disposed in the main molten pool, and at least one second temperature sensor disposed in the refining pool.

2. The electric melting furnace for producing glass beads according to claim 1, characterized in that, The heating element positioned above the main molten pool is a silicon carbide rod.

3. The electric melting furnace for producing glass beads according to claim 1, characterized in that, The discharge port includes a first discharge port located in the bottom area of ​​the main molten pool.

4. The electric melting furnace for producing glass beads according to claim 1, characterized in that, The second electrode includes a pair of electrodes adapted to be vertically inserted into the clarification tank from above, and the second temperature sensor is disposed between the pair of electrodes.

5. The electric melting furnace for producing glass beads according to claim 1, characterized in that, The discharge outlets include two second discharge outlets located in the bottom area of ​​the clarification tank.

6. The electric melting furnace for producing glass beads according to any one of claims 1-5, characterized in that, It also includes a control system for receiving temperature signals from temperature sensors and adjusting the power supplied to the heating element, the first electrode, and the second electrode based on the temperature signals to control the temperature in the main molten pool and the refining pool.

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