Electrode structure for improving homogeneous melting of glass melt

Abstract

The utility model discloses an electrode structure of promoting glass liquid uniform melting belongs to base plate glass production technical field. This electrode structure is through the layered setting upper electrode, middle layer electrode and lower electrode, forms multistage heating area in kiln longitudinal, cooperates pool wall both sides symmetrical distribution design and the isolation effect of electrode interval pool wall, realized the independent temperature control of kiln longitudinal different height area. The physical separation of electrode interval pool wall effectively avoids the electric field interference of adjacent heating area, ensures the independent adjusting ability of each layer electrode electric parameter. The electrode layout of symmetrical distribution has guaranteed the uniformity of kiln longitudinal temperature field, avoids the local overheating or underheating phenomenon. The electrode structure of the utility model is through longitudinal layering independent temperature control and the design of differentiation promotion, realizes the process temperature accurate matching and electrode loss balance, significantly promotes glass liquid melting quality and prolongs electrode service life.

Description

Technical Field

[0001] This utility model belongs to the field of substrate glass production technology, and specifically relates to an electrode structure that improves the uniform melting of molten glass. Background Technology

[0002] In the glass manufacturing industry, the glass furnace, as the core equipment for melting glass batches into molten glass, directly affects the quality and production cost of the final glass product due to its temperature control accuracy and electrode operating efficiency. Traditional glass furnace electrode designs generally adopt an integrated layout structure. While this design can meet basic melting requirements, it faces two major technical bottlenecks in actual production: firstly, the longitudinal temperature field control lacks precision; secondly, electrode loss management has significant limitations.

[0003] The melting process of glass batches involves multiple continuous stages, including melting, refining, and homogenization. Each stage has significantly different requirements for the longitudinal temperature distribution of the furnace. In the melting stage, a higher top temperature is needed to rapidly complete the physicochemical changes of the batch. In the refining stage, a relatively stable temperature gradient needs to be maintained in the middle region to promote bubble removal. The homogenization stage requires even stricter uniformity of the bottom temperature to ensure the homogeneity of the glass melt composition. However, existing integral electrode structures can only achieve coarse control of the transverse temperature of the furnace through single parameter adjustment, failing to implement differentiated temperature management for different longitudinal height regions. This technical deficiency directly leads to a mismatch between the temperature field distribution within the furnace and the process requirements, easily causing problems such as fluctuations in glass melt viscosity, increased bubble residue, and increased streak defects, ultimately resulting in a decrease in product qualification rate and low energy utilization.

[0004] Traditional integral propulsion electrode systems exhibit non-uniform consumption rates across different electrode sections due to variations in the electric field distribution, thermal radiation intensity, and longitudinal differences in the flow state of the molten glass within the furnace. Electrode sections near the top of the melting zone, subjected to higher current densities and more intense thermal shocks, tend to oxidize and corrode faster than the middle and lower sections. Meanwhile, the bottom electrode sections, constantly immersed in the high-temperature molten glass environment, may experience excessive wear due to chemical erosion and mechanical scouring. However, current technology can only adjust electrode positions by uniformly increasing the propulsion speed. This "one-size-fits-all" approach inevitably leads to some areas of the electrode reaching their service life prematurely, forcing companies to frequently shut down the furnace to replace electrode components.

[0005] As modern glass products develop towards higher precision and multi-functionality, the market's quality requirements for high-end products such as optical glass and electronic glass continue to rise. This necessitates more precise temperature control and more reliable equipment stability in the production process. However, the limitations of existing technologies not only restrict the potential for improving product performance but also fall short of the current trend in the glass industry towards high efficiency, energy conservation, and low carbon emissions under the context of intelligent manufacturing. Summary of the Invention

[0006] The purpose of this invention is to overcome the above-mentioned problems and provide an electrode structure that improves the uniform melting of molten glass, enabling precise matching of the melting process temperature and balanced electrode wear, significantly improving the melting quality of molten glass and extending the service life of the electrode.

[0007] To achieve the above objectives, the present invention adopts the following technical solution: This utility model provides an electrode structure for improving the uniform melting of molten glass, including an electrode, a pool wall, and a pool bottom, wherein the electrode, pool wall, and pool bottom form a closed area of ​​the furnace; The electrode includes an upper electrode, a middle electrode, and a lower electrode. The upper electrode, the middle electrode, and the lower electrode are arranged in layers along the longitudinal direction of the kiln, and an electrode spacer wall is provided between the upper electrode, the middle electrode, and the lower electrode. The upper, middle, and lower electrodes are symmetrically arranged on the left and right sides of the pool wall.

[0008] A further improvement of this utility model is that the upper electrode includes an upper left electrode and an upper right electrode, which are symmetrically arranged on the upper layer of the kiln pool wall.

[0009] A further improvement of this invention is that the middle layer electrode includes a middle layer left electrode and a middle layer right electrode, which are symmetrically arranged in the middle layer of the kiln pool wall.

[0010] A further improvement of this utility model is that the lower electrode includes a lower left electrode and a lower right electrode, which are symmetrically arranged in the lower layer of the kiln pool wall.

[0011] A further improvement of this invention is that the number of layers of the longitudinally arranged electrodes is ≥2.

[0012] A further improvement of this invention is that each layer of electrodes is arranged in pairs on the cross-section of the kiln, including at least one set of left and right electrodes arranged opposite to each other.

[0013] A further improvement of this invention is that the thickness of the electrode spacer wall between the upper electrode, the middle electrode and the lower electrode is 50~200mm.

[0014] A further improvement of this utility model is that the kiln enclosed area includes an upper enclosed area, a middle enclosed area, and a lower enclosed area.

[0015] A further improvement of this utility model is that the total length of the upper layer electrode in the front zone electrode of the kiln is less than the total length of the middle layer electrode, which is less than the total length of the lower layer electrode. In the kiln's middle and rear zones, the total length of the upper layer electrodes is equal to the total length of the middle layer electrodes, which in turn is equal to the total length of the lower layer electrodes.

[0016] A further improvement of this invention is that the electrode spacer wall and the layered electrodes together form an independent power supply circuit, so that the upper electrode, the middle electrode and the lower electrode form an electrically isolated heating area.

[0017] Compared with the prior art, the present invention has the following beneficial effects: This invention provides an electrode structure for improving the uniform melting of molten glass. This electrode structure, through a layered arrangement of upper, middle, and lower electrodes, forms multi-level heating zones along the longitudinal direction of the furnace. Combined with a symmetrical distribution design on both sides of the tank wall and the isolation effect of the electrode spacing walls, it achieves independent temperature control for different height areas along the longitudinal direction of the furnace. This layered structure allows the upper electrode to be specifically adjusted to meet the high-temperature requirements of the initial melting stage, the middle electrode to maintain a stable temperature gradient during the clarification stage, and the lower electrode to optimize the bottom uniformity during the homogenization stage, thereby precisely matching the process temperature requirements of the glass batch at each stage of melting, clarification, and homogenization. The physical separation of the electrode spacing walls effectively avoids electric field interference between adjacent heating zones, ensuring the independent adjustment capability of the electrical parameters of each electrode layer. The symmetrical electrode layout ensures the uniformity of the longitudinal temperature field of the furnace, avoiding localized overheating or underheating. This invention's electrode structure, through independent temperature control in a longitudinal layered manner, achieves precise matching of process temperature and balanced electrode wear, significantly improving the melting quality of molten glass and extending electrode life.

[0018] Furthermore, the number of layers of the longitudinally arranged electrodes is ≥2 layers, and each layer of electrodes is arranged in pairs on the cross-section of the furnace, including at least one set of left and right electrodes arranged opposite to each other. Through the coordinated layout of multiple sets of electrodes, the dual advantages of continuous thermal field coverage and flexible process control are achieved. This not only eliminates the thermal blind zone of traditional single-set electrodes, but also allows for independent adjustment of parameters of each set according to the needs of different melting stages. At the same time, the system reliability is improved through redundant design, providing a precise and controllable heating environment for uniform melting of molten glass.

[0019] Furthermore, the thickness of the electrode spacer wall between the upper, middle, and lower electrodes is 50-200 mm. This ensures structural strength while achieving precise control of the thermal field. This thickness range effectively isolates the thermal field of each electrode layer and maintains the overall structural stability of the kiln. By balancing thermal isolation effect and space utilization, it provides flexible options for different process requirements, fundamentally solving the contradiction between interlayer thermal interference and space waste in traditional structures. Attached Figure Description

[0020] The accompanying drawings described herein are for illustrative purposes only and are not intended to limit the scope of the present invention in any way. Furthermore, the shapes and proportions of the components in the drawings are merely illustrative to aid in understanding the present invention and do not specifically limit the shapes and proportions of the components of the present invention.

[0021] Figure 1 This is a schematic diagram of the electrode structure for improving the uniform melting of molten glass according to this invention.

[0022] Among them: 1. Electrode; 11. Upper electrode; 111. Upper left electrode; 112. Upper right electrode; 12. Middle electrode; 121. Middle left electrode; 122. Middle right electrode; 13. Lower electrode; 131. Lower left electrode; 132. Lower right electrode; 2. Pool wall; 21. Electrode spacer pool wall; 3. Pool bottom; 4. Kiln enclosed area; 41. Upper enclosed area of ​​kiln; 42. Middle enclosed area of ​​kiln; 43. Lower enclosed area of ​​kiln. Detailed Implementation

[0023] To make the objectives, technical solutions, and advantages of the embodiments of this utility model clearer, the technical solutions of the embodiments of this utility model will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of this utility model, and not all embodiments. The components of the embodiments of this utility model described and shown in the accompanying drawings can generally be arranged and designed in various different configurations.

[0024] Therefore, the following detailed description of the embodiments of the present 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 present invention without inventive effort are within the scope of protection of the present invention.

[0025] It should be noted that similar labels and letters in the following figures indicate similar items. Therefore, once an item is defined in one figure, it does not need to be further defined and explained in subsequent figures.

[0026] In the description of the embodiments of this utility model, it should be noted that if terms such as "upper," "lower," "horizontal," or "inner" indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings, or the orientation or positional relationship commonly used when the utility model product is in use, they are only for the convenience of describing the utility model and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation on the utility model. Furthermore, terms such as "first" and "second" are only used to distinguish descriptions and should not be construed as indicating or implying relative importance.

[0027] Furthermore, the use of the term "horizontal" does not imply that the component must be absolutely horizontal, but rather that it can be slightly tilted. For example, "horizontal" simply means that its direction is more horizontal than "vertical," and does not mean that the structure must be completely horizontal, but can be slightly tilted.

[0028] In the description of the embodiments of this utility model, it should also be noted that, unless otherwise explicitly specified and limited, the terms "set," "install," "connect," and "link" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; and they can refer to the internal connection of two components. Those skilled in the art can understand the specific meaning of the above terms in this utility model according to the specific circumstances.

[0029] The present invention will now be described in further detail with reference to the accompanying drawings: like Figure 1 As shown, this utility model provides an electrode structure for improving the uniform melting of molten glass, including an electrode 1, a pool wall 2, and a pool bottom 3. The electrode 1, pool wall 2, and pool bottom 3 form a closed area 4 of the furnace. The electrode 1 includes an upper electrode 11, a middle electrode 12, and a lower electrode 13. The upper electrode 11, middle electrode 12, and lower electrode 13 are arranged in layers along the longitudinal direction of the furnace to heat molten glass at different depths. An electrode spacer pool wall 21 is provided between each of the upper electrode 11, middle electrode 12, and lower electrode 13. The electrode spacer pool wall 21 between the upper electrode 11, middle electrode 12, and lower electrode 13 can ensure that the thermal fields of each layer do not interfere with each other, so as to maintain a stable temperature gradient. The upper electrode 11, middle electrode 12, and lower electrode 13 are symmetrically arranged on the left and right sides of the pool wall 2 to eliminate the temperature unevenness caused by unilateral heating.

[0030] The electrode spacer wall 21 and the layered electrodes 1 together form an independent power supply circuit, so that the upper electrode 11, the middle electrode 12 and the lower electrode 13 form an electrically isolated heating area.

[0031] The kiln enclosed area 4 includes the upper enclosed area 41, the middle enclosed area 42, and the lower enclosed area 43.

[0032] The upper electrode 11, middle electrode 12, and lower electrode 13 are powered independently and do not interfere with each other. Specifically, the upper left electrode 111 and upper right electrode 112 of the upper electrode 11 form an upper circuit with the molten glass in the enclosed area 41 of the furnace; the middle left electrode 121 and middle right electrode 122 of the middle electrode 12 form a middle circuit with the molten glass in the enclosed area 42 of the furnace; and the lower left electrode 131 and lower right electrode 132 of the lower electrode 13 form a lower circuit with the molten glass in the enclosed area 43 of the furnace. The upper circuit focuses on controlling the flow state of the surface glass liquid, the middle circuit dominates the heat conduction of the core melting zone, and the lower circuit ensures the complete dissolution of deep materials. Each circuit can independently adjust the current parameters according to the material state, avoiding the energy waste caused by traditional overall heating. At the same time, the on-demand power supply of each layer significantly reduces ineffective heat loss, and the symmetrical circuit design improves the efficiency of power utilization.

[0033] The upper electrode 11 includes an upper left electrode 111 and an upper right electrode 112, which are symmetrically arranged on the upper layer of the kiln pool wall 2. The middle electrode 12 includes a middle left electrode 121 and a middle right electrode 122, which are symmetrically arranged on the middle layer of the kiln pool wall 2. The lower electrode 13 includes a lower left electrode 131 and a lower right electrode 132, which are symmetrically arranged on the lower layer of the kiln pool wall 2.

[0034] The number of layers of the longitudinally arranged electrodes 1 is ≥2 layers. The number of longitudinal layers refers to the number of independent electrode layers arranged along the height of the kiln, including but not limited to a two-layer structure or a three-layer structure. Each layer of electrodes 1 is arranged in pairs on the cross-section of the kiln, including at least one set of oppositely arranged left and right electrodes. The number of transverse groups is the number of pairs of electrodes arranged around the kiln, preferably 1-3 pairs / layer.

[0035] The thickness of the electrode spacer wall 21 between the upper electrode 11, the middle electrode 12 and the lower electrode 13 is 50~200mm. While ensuring structural strength, it achieves precise control of the thermal field. This thickness range can effectively isolate the thermal field of each electrode 1 layer and maintain the overall structural stability of the kiln. By balancing the thermal isolation effect and space utilization, it provides flexible selection space for different process requirements and fundamentally solves the contradiction between interlayer thermal interference and space waste in traditional structures.

[0036] This utility model provides a method for controlling the electrode structure to improve the uniform melting of molten glass, comprising the following steps: Step 1: The electrode 1 is divided into three layers along the longitudinal direction of the kiln: upper electrode 11, middle electrode 12 and lower electrode 13. Step 2: Based on the incoming material, supply power independently to the upper electrode 11, the middle electrode 12 and the lower electrode 13 to form independent current loops; Step 3: Differentiated electrode advancement is performed on the upper electrode 11, middle electrode 12 and lower electrode 13 according to the lateral position of electrode 1.

[0037] As a preferred embodiment, the current magnitudes of the upper electrode 11, middle electrode 12, and lower electrode 13 are set according to the different regions where the molten glass is located, as follows: (1) The front area is close to the melting area of ​​the feeding port. Affected by the incoming material or abnormal disturbance of the furnace, the glass melt will be layered in the longitudinal direction. That is, the incoming material above cannot be melted in time and sinks down, which causes the temperature of the glass melt in the longitudinal direction to gradually decrease from bottom to top, which is not conducive to the stable melting of the glass melt. In the area where the glass sample temperature is low, the temperature can be increased by increasing the current. In the area where the temperature is high, the temperature can be reduced by decreasing the current. That is, the longitudinal temperature can be adjusted by the difference of the current, so as to achieve efficient and uniform melting of the glass melt and rapid recovery under abnormal disturbance of the furnace. That is, the current of the upper electrode 11 in this area is < the current of the middle electrode 12 < the current of the lower electrode 13. (2) In the pre-clarification zone of the kiln, it is necessary to maintain a temperature layout that is higher at the top and lower at the bottom and to maintain a reasonable gradient, which can better promote the discharge of bubbles. By adjusting the current differently, a reasonable temperature gradient setting for the glass melt in the pre-clarification zone can be achieved, that is, the current of the upper electrode 11 in this zone is greater than the current of the middle electrode 12 and the current of the lower electrode 13. (3) In the kiln outlet area, it is necessary to ensure the uniformity of the glass sample temperature to ensure the uniformity of the glass liquid composition, so as to provide high-quality glass samples for subsequent processes. That is, the current of the upper electrode 11 in this area = the current of the middle electrode 12 = the current of the lower electrode 13.

[0038] The specific method for differentially advancing the upper electrode 11, middle electrode 12, and lower electrode 13 is as follows: In the front zone electrode 1 of the kiln, the advancing amount of the upper electrode 11 is less than the advancing amount of the middle electrode 12, which is less than the advancing amount of the lower electrode 13; in the middle and rear zone electrodes 1 of the kiln, the advancing amount of the upper electrode 11 is equal to the advancing amount of the middle electrode 12, which is equal to the advancing amount of the lower electrode 13.

[0039] In the front zone electrode 1 of the kiln, the total length of the upper electrode 11 is less than the total length of the middle electrode 12, which is less than the total length of the lower electrode 13; in the middle and rear zone electrodes 1 of the kiln, the total length of the upper electrode 11 is equal to the total length of the middle electrode 12, which is equal to the total length of the lower electrode 13.

[0040] The electrodes in the melting area near the feed inlet in the front zone of the kiln experience slower consumption due to the influence of incoming material. The temperature near the upper electrodes is lower, while the temperature of the lower electrodes increases sequentially, leading to faster consumption. Simultaneous advancement of the upper electrode 11, middle electrode 12, and lower electrode 13 would result in excessive residue of the upper electrode 11 inside the glass sample, affecting the heating of the sample and consequently impacting the stability of the kiln operation. Differentiated advancement promotes stable and efficient melting of the glass sample and extends the service life of the electrodes. By designing differentiated vertical electrodes in the initial state based on the varying consumption levels of the upper, middle, and lower electrodes 11, construction costs can be effectively reduced.

[0041] The advancement amounts of the upper electrode 11, middle electrode 12, and lower electrode 13 are obtained by combining the actual efficiency rates of the upper electrode 11, middle electrode 12, and lower electrode 13 after kiln dismantling with the consumption rates simulated by software. Specifically, this is achieved through the following collaborative mechanism: (1) Analysis of actual consumption rate: During the kiln dismantling and maintenance cycle, the remaining amount of the upper electrode 11, middle electrode 12 and lower electrode 13 is collected in real time. Combined with the running time of electrode 1, the actual average consumption rate of each layer of electrode 1 in the longitudinal dimension is calculated. (2) Multi-temperature zone simulation verification: Based on the longitudinal temperature gradient distribution characteristics of the kiln, an electrode consumption kinetic model was established using thermochemical simulation software to simulate the average longitudinal consumption rate of each layer of electrodes under different temperature conditions. (3) Dual-source data fusion: The measured consumption rate and the simulated consumption rate are weighted and coupled for analysis. The system error is eliminated by dynamic calibration algorithm to generate the optimized consumption rate prediction value of each electrode layer.

[0042] This method effectively overcomes the limitations of traditional single evaluation methods by integrating physical measurement data and digital simulation results, significantly improves the accuracy of electrode consumption prediction, and provides core technical support for electrode life management and kiln energy efficiency optimization.

[0043] Many embodiments and applications beyond the examples provided will be apparent to those skilled in the art upon reading the foregoing description. Therefore, the scope of this teaching should not be determined by reference to the foregoing description, but rather by reference to the foregoing claims and the full scope of their equivalents. For purposes of completeness, all articles and references, including patent applications and publications, are incorporated herein by reference. The omission of any aspect of the subject matter disclosed herein in the foregoing claims is not intended as a waiver of that subject matter, nor should it be construed as an indication that the applicant has not considered that subject matter as part of the disclosed utility model subject matter.

[0044] The above content provides a further detailed description of this utility model. It should not be considered that the specific embodiments of this utility model are limited to this. For those skilled in the art, several simple deductions or substitutions can be made without departing from the concept of this utility model, and all such deductions or substitutions should be considered to fall within the scope of protection of this utility model as defined by the submitted claims.

Claims

1. An electrode structure for improving the uniform melting of molten glass, characterized in that, Includes electrodes (1), pool walls (2) and pool bottom (3), which together form a closed area (4) of the kiln. The electrode (1) includes an upper electrode (11), a middle electrode (12) and a lower electrode (13). The upper electrode (11), the middle electrode (12) and the lower electrode (13) are arranged in layers along the longitudinal direction of the kiln, and an electrode spacer wall (21) is provided between the upper electrode (11), the middle electrode (12) and the lower electrode (13). The upper electrode (11), middle electrode (12) and lower electrode (13) are symmetrically arranged on the left and right sides of the pool wall (2).

2. The electrode structure for improving the uniform melting of molten glass according to claim 1, characterized in that, The upper electrode (11) includes an upper left electrode (111) and an upper right electrode (112), which are symmetrically arranged on the upper layer of the kiln pool wall (2).

3. The electrode structure for improving the uniform melting of molten glass according to claim 1, characterized in that, The middle layer electrode (12) includes a middle layer left electrode (121) and a middle layer right electrode (122), which are symmetrically arranged in the middle layer of the kiln pool wall (2).

4. The electrode structure for improving the uniform melting of molten glass according to claim 1, characterized in that, The lower electrode (13) includes a lower left electrode (131) and a lower right electrode (132), which are symmetrically arranged in the lower layer of the kiln pool wall (2).

5. The electrode structure for improving the uniform melting of molten glass according to claim 1, characterized in that, The number of layers of the longitudinally arranged electrodes (1) is ≥2.

6. The electrode structure for improving the uniform melting of molten glass according to claim 1, characterized in that, Each layer of electrodes (1) is arranged in pairs on the cross-section of the kiln, including at least one set of left and right electrodes arranged opposite to each other.

7. The electrode structure for improving the uniform melting of molten glass according to claim 1, characterized in that, The thickness of the electrode spacer wall (21) between the upper electrode (11), the middle electrode (12) and the lower electrode (13) is 50~200mm.

8. The electrode structure for improving the uniform melting of molten glass according to claim 1, characterized in that, The kiln enclosure area (4) includes the upper enclosure area (41), the middle enclosure area (42), and the lower enclosure area (43).

9. The electrode structure for improving the uniform melting of molten glass according to claim 1, characterized in that, The total length of the upper electrode (11) in the front zone electrode (1) of the kiln is less than the total length of the middle electrode (12) and less than the total length of the lower electrode (13); The total length of the upper layer electrode (11) of the middle and rear zone electrodes of the kiln is equal to the total length of the middle layer electrode (12) and the total length of the lower layer electrode (13).

10. The electrode structure for improving the uniform melting of molten glass according to claim 1, characterized in that, The electrode spacer wall (21) and the layered electrodes (1) together form an independent power supply circuit, so that the upper electrode (11), the middle electrode (12) and the lower electrode (13) form an electrically isolated heating area.

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