Apparatus and method for cooling the wall of a glass melting vessel

Abstract

A glass manufacturing apparatus includes a melting vessel with one or more cooling panels disposed adjacent one or more walls of the melting vessel, each cooling panel including a passage therethrough through which a cooling fluid flows, the cooling fluid extracting heat from the melting vessel walls to reduce the temperature of the melting vessel, thereby reducing degradation of the melting vessel walls and extending the life of the melting vessel.

Description

[Technical Field]

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS This application claims the benefit of priority under 35 U.S.C. § 119 of U.S. Provisional Patent Application Serial No. 63 / 217,519, filed July 1, 2021, the contents of which are reliably incorporated herein by reference in their entirety.

[0002] FIELD OF THE DISCLOSURE The present disclosure relates generally to glass manufacturing apparatus and methods, and more particularly to glass manufacturing apparatus and methods that cool the walls of a glass melting vessel to extend the life of the glass melting vessel. [Background technology]

[0003] The need to keep melting vessels operating at high molten glass flow rates for extended periods of time places a strain on the refractory materials used in their construction. A typical melting vessel is formed from layers of refractory material (e.g., firebrick and / or block). The molten glass contained in the melting vessel can erode the refractory material over time, for example, due to flow erosion and the high temperature and corrosive nature of the molten glass. Eventually, the refractory material wears out, the melting vessel is compromised, and a new melting vessel must be constructed. Reconstructing the structure can result in long periods of lost production and can be costly. Therefore, there is a desire to delay shutdowns and rebuilds as much as possible by slowing the deterioration of the melting vessel. Summary of the Invention [Means for solving the problem]

[0004] The following presents a simplified summary of the disclosure in order to provide a basic understanding of some embodiments described in the detailed description. These and other features, aspects, and advantages will be better understood by reading the following detailed description in conjunction with the accompanying drawings.

[0005] Disclosed is a glass manufacturing apparatus comprising a melting vessel including a refractory glass contact wall, and a cooling panel configured to receive a cooling fluid through an inlet port and discharge the cooling fluid through an outlet port, wherein the cooling panel contacts and is biased against the refractory glass contact wall by a pressure bolt contacting the cooling panel.

[0006] The inlet port may be located in the lower half of the cooling panel and the outlet port may be located in the upper half of the cooling panel.

[0007] In some embodiments, the refractory glass contact wall comprises a sidewall of the melting vessel.

[0008] In various embodiments, the cooling panel includes a serpentine passage extending within the cooling panel between the inlet and outlet ports.

[0009] In some embodiments, the cooling panel includes a base portion and a cover portion, where the serpentine path is machined into the base portion and the cover portion is attached to the base portion, for example, using one or more fasteners, although in further embodiments the cover portion can be permanently attached to the base portion, such as by welding. The base portion can be positioned against the fire-resistant glass contact wall.

[0010] In some embodiments, the base portion includes a back surface that includes a recess formed therein, and a compatible thermally conductive material can be disposed within the recess between the cooling panel and the fire-resistant glass contact wall.

[0011] In some embodiments, the cooling panel includes at least one thermocouple.

[0012] In some embodiments, the melting vessel includes a plurality of cooling panels in contact with and biased against the refractory glass contact wall. The plurality of cooling panels may be supplied with cooling fluid through a single cooling fluid header. Each cooling panel may be supplied from the cooling fluid header through a cooling liquid line, the cooling liquid line for each cooling panel including an isolation valve.

[0013] In some embodiments, the cooling panel may be provided with at least one handle to aid in installation of the cooling panel.

[0014] The pressure bolt can be disposed between the brace member and the cooling panel, the pressure bolt being coupled to the brace member. In some embodiments, multiple pressure bolts can be used to secure the cooling panel to the melt vessel.

[0015] In some embodiments, the glass manufacturing apparatus can further include a metal grid panel in contact with and biased against the fire-resistant glass contact wall. For example, the metal grid panel can be positioned below the cooling panel.

[0016] In some embodiments, the metal grid panels may be at least partially supported by one or more refractory blocks positioned below the metal grid panels.

[0017] In some embodiments, the melting vessel can include a second metal grid panel in contact with and biased against the fire-resistant glass contact wall, the second metal grid panel being positioned above the cooling panel.

[0018] The following detailed description sets forth additional features of the embodiments disclosed herein, which will become apparent in part to those skilled in the art from the description, including the claims and accompanying drawings. Both the foregoing summary and the following detailed description present embodiments intended to provide an overview or framework for understanding the nature and character of the embodiments. The accompanying drawings are included to provide a further understanding and are incorporated into and constitute a part of this specification. These drawings illustrate various embodiments of the present disclosure and, together with the description, explain the principles and operation of the various embodiments. [Brief explanation of the drawings]

[0019] [Figure 1] 1 is a schematic diagram of an exemplary glass manufacturing apparatus. [Figure 2] FIG. 1 is a perspective view of an exemplary melting vessel. [Figure 3] FIG. 2 is a top view of the interior of an exemplary melting vessel. [Figure 4] FIG. 1 is a perspective view of an exemplary melt vessel disposed within a rigid exoskeleton. [Figure 5] 3 is a cross-sectional view of an exemplary lower refractory sidewall of the melting vessel of FIG. 2. [Figure 6] FIG. 5 is an exploded cross-sectional view of an exemplary cooling panel taken along line 5-5 of FIG. 6 according to embodiments disclosed herein. [Figure 7] 6 is a top view of the base portion of the cooling panel of FIG. 5 showing the serpentine passageway formed by multiple walls, such as baffles, extending therethrough. [Figure 8] FIG. 6 is a top view of the cover portion of the cooling panel of FIG. 5. [Figure 9] FIG. 5 is a side view of the cooling panel shown in FIG. 4 positioned against the lower refractory side wall of the melting vessel. [Figure 10] FIG. 1 is a schematic diagram of a pressure bolt connecting a melt vessel or a component thereof to a rigid exoskeleton according to one or more embodiments shown and described herein. DETAILED DESCRIPTION OF THE INVENTION

[0020] Reference will now be made in detail to the embodiments of the present disclosure, examples of which are illustrated in the accompanying drawings. Wherever possible, the same reference numbers will be used throughout the drawings to refer to the same or like parts. This disclosure may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein.

[0021] As used herein, the term "about" means that a quantity, size, composition, parameter, and other quantity and characteristic is not or need not be exact, but is approximate and / or larger or smaller, as appropriate, to reflect tolerances, conversion factors, rounding, measurement error, and the like, as well as other factors well known to those skilled in the art.

[0022] Ranges may be expressed herein as from "about" one particular value, and / or to "about" another particular value. When such a range is expressed, another embodiment includes from the one particular value to the other particular value. Similarly, when values ​​are expressed as approximations, by the use of the antecedent "about," it will be understood that the value forms another embodiment. It will further be understood that the endpoints of each range can be understood both in relation to the other endpoint, and independently of the other endpoint.

[0023] As used herein, directional terms such as up, down, right, left, front, back, top, bottom, etc. are used with reference to the figures only and do not imply absolute orientation.

[0024] Unless expressly stated otherwise, no method set forth herein should be construed as requiring that its steps be performed in a particular order, and no apparatus should be construed as requiring a particular orientation. Thus, unless a method claim actually recites the order in which its steps must be followed, or any apparatus claim actually recites an order or orientation for individual components, or unless the claim or this specification otherwise specifically indicates that the steps are to be limited to a particular order, or does not recite a particular order or orientation for the apparatus components, no order or orientation is to be implied in any way. This applies to all possible non-express basis for interpretation, including logical matters regarding step sequence, operational flow, component order or component orientation, general meanings derived from grammatical construction or punctuation, and the number or type of embodiments described herein.

[0025] As used herein, the singular indefinite articles "a," "an," and "the" include plural references unless the context clearly dictates otherwise. Thus, for example, the phrase "a component" includes aspects having two or more such components, unless the context clearly dictates otherwise.

[0026] As used herein, the words "exemplary," "example," or various forms thereof mean serving as an example, instance, or illustration. Any aspect or design described herein as "exemplary" or "example" is not to be construed as preferred or advantageous over other aspects or designs. Moreover, examples are merely set forth for purposes of clarity and understanding and are not meant to limit or restrict in any way the disclosed subject matter or relevant portions of this disclosure. Numerous additional or alternative examples of varying scope could have been presented but have been omitted for the sake of brevity.

[0027] As used herein, the terms "comprising" and "including," and variations thereof, should be construed as synonymous and inclusive unless otherwise indicated. The list of elements following the transitional phrase "comprising" or "including" is a non-exclusive list, and therefore, there may be elements other than those specifically listed in the list.

[0028] As used herein, the terms "substantial," "substantially," and variations thereof, are intended to indicate that a described feature is equal to or approximately equal to a value or description. For example, a "substantially planar" surface is intended to indicate a surface that is planar or approximately planar. Furthermore, "substantially" is intended to indicate that two values ​​are equal or approximately equal. In some embodiments, "substantially" can indicate values ​​within about 10% of each other, such as within about 5% of each other or within about 2% of each other.

[0029] As used herein, "refractory" means a non-metallic material having chemical and physical properties that permit its application to components of structures or systems exposed to environments above 538°C.

[0030] 1 illustrates an exemplary glass manufacturing apparatus 10. In some embodiments, the glass manufacturing apparatus 10 can include a glass melting furnace 12 including a melting vessel 14. In addition to the melting vessel 14, the glass melting furnace 12 can optionally include one or more additional components, such as a heating element (e.g., a combustion burner and / or electrodes) configured to heat the raw materials and convert the raw materials into molten glass. For example, the melting vessel 14 can be an electrically-boosted melting vessel in which energy is added to the raw materials by both a combustion burner and direct heating, in which an electric current is applied to the raw materials via Joule heating of the raw materials by passing an electric current through the raw materials.

[0031] In further embodiments, the glassmelting furnace 12 may include other thermal management devices (e.g., isolation components) that reduce heat loss from the melting vessel. In further embodiments, the glassmelting furnace 12 may include electronic and / or electromechanical devices that facilitate melting of the raw materials into a glass melt. The glassmelting furnace 12 may also include support structures (e.g., support chassis, support members, etc.) or other components.

[0032] The melting vessel 14 can be formed from a refractory material, such as a refractory ceramic material including, for example, alumina or zirconia, although the refractory ceramic material can also include other refractory materials, such as yttrium (e.g., yttria, yttria-stabilized zirconia, yttrium phosphate), zircon (ZrSiO4), or alumina-zirconia-silica, or chromium oxide, used alternatively or in any combination. In some embodiments, the melting vessel 14 can be constructed from refractory ceramic bricks.

[0033] In some embodiments, the glass melting furnace 12 can be incorporated as a component of a glass manufacturing apparatus configured to produce glass articles such as, for example, a glass ribbon, while in further embodiments, the glass manufacturing apparatus can be configured to form other glass articles such as, without limitation, glass rods, glass tubes, glass envelopes (e.g., glass envelopes for lighting devices such as light bulbs), and glass lenses, although many other glass articles are contemplated. In some examples, the melting furnace can be included in a glass manufacturing apparatus including a slot draw apparatus, a float bath apparatus, a downdraw apparatus (e.g., a fusion downdraw apparatus), an updraw apparatus, a pressing apparatus, a rolling apparatus, a tube drawing apparatus, or any other glass manufacturing apparatus that would benefit from the present disclosure. By way of example, FIG. 1 schematically illustrates a glass melting furnace 12 as a component of a fusion downdraw glass manufacturing apparatus 10 that fusion draws a glass ribbon for subsequent processing into individual glass sheets or winding the glass ribbon onto a spool. As used herein, the fusion draw process involves flowing molten glass onto the converging surfaces of a forming body so that the two resulting streams of molten material meet or "fuse" at the bottom of the forming body along a converging line.

[0034] Optionally, glass manufacturing system 10 may include upstream glass manufacturing equipment 16 disposed upstream of melting vessel 14. In some examples, part or all of upstream glass manufacturing equipment 16 may be incorporated as part of glassmelting furnace 12.

[0035] As shown in the embodiment depicted in FIG. 1 , the upstream glass-making apparatus 16 can include a raw material storage bin 18, a raw material delivery device 20, and a motor 22 connected to the raw material delivery device 20. The raw material storage bin 18 can be configured to store an amount of raw material 24 that can be supplied to the melting vessel 14 of the glass melting furnace 12 through one or more feed ports, as indicated by arrow 26. Typically, the raw material 24 includes one or more glass-forming metal oxides and one or more modifiers. In some examples, the raw material delivery device 20 can be driven by the motor 22 to deliver a predetermined amount of raw material 24 from the raw material storage bin 18 to the melting vessel 14. In a further example, the motor 22 can drive the raw material delivery device 20 to introduce the raw material 24 at a controlled rate based on a level of molten glass sensed downstream from the melting vessel 14 relative to the flow direction of the molten glass. The raw material 24 in the melting vessel 14 can then be heated to form molten glass 28. Typically, in an initial melting step, raw material is added to the melting vessel as particulate matter, such as various types of “sand.” The raw material 24 may also include waste glass (i.e., cullet) from previous melting and / or forming operations. Typically, a combustion burner is used to initiate the melting process. In an electrically boosted melting process, once the electrical resistance of the raw material is sufficiently reduced, an electrical boost can be initiated by generating an electrical potential between electrodes placed in contact with the raw material, which typically results in an electrical current being established through the raw material as it enters or is in a molten state. The resulting molten material is referred to herein as molten glass.

[0036] Optionally, glass manufacturing system 10 may also include downstream glass manufacturing equipment 30 disposed downstream of glass melting furnace 12 relative to the flow direction of molten glass 28. In some examples, a portion of downstream glass manufacturing equipment 30 may be incorporated as part of glass melting furnace 12. However, in some instances, a first connecting conduit 32, described below, or other portions of downstream glass manufacturing equipment 30 may be incorporated as part of glass melting furnace 12.

[0037] The downstream glass manufacturing apparatus 30 may include a first conditioning (i.e., processing) chamber, such as a fining vessel 34, disposed downstream from the melting vessel 14 and coupled to the melting vessel 14 by the first connecting conduit 32 described above. In some examples, the molten glass 28 may be gravity-fed from the melting vessel 14 to the fining vessel 34 via the first connecting conduit 32. For example, gravity may drive the molten glass 28 from the melting vessel 14 to the fining vessel 34 through the internal passage of the first connecting conduit 32. Thus, the first connecting conduit 32 provides a flow path for the molten glass 28 from the melting vessel 14 to the fining vessel 34. However, it should be understood that other conditioning chambers may be disposed downstream of the melting vessel 14, such as between the melting vessel 14 and the fining vessel 34. In some embodiments, a conditioning chamber may be employed between the melting vessel and the fining chamber. For example, the molten glass from the primary melting vessel may be further heated in a secondary melting (conditioning) vessel or cooled in the secondary melting vessel to a temperature lower than that of the molten glass in the primary melting vessel before entering the fining chamber.

[0038] As mentioned above, gas bubbles can be removed from the molten glass 28 by various techniques. For example, the raw material 24 can include multivalent compounds (i.e., fining agents), such as tin oxide, that undergo a chemical reduction reaction upon heating to release oxygen. Other suitable fining agents include, but are not limited to, arsenic, antimony, iron, and / or cerium; however, arsenic and antimony are toxic and may not be recommended for some applications for environmental reasons. The fining vessel 34 is heated, for example, to a temperature higher than the internal temperature of the melting vessel, thereby heating the fining agents. Oxygen generated by the temperature-induced chemical reduction of one or more fining agents in the molten glass can increase through the molten glass in the fining vessel and coalesce or diffuse into gas bubbles created during the melting process. This causes enlarged, more buoyant gas bubbles to rise to the free surface of the molten glass in the fining vessel, where they can then be removed from the fining vessel.

[0039] The downstream glass-making apparatus 30 may further include another conditioning chamber, e.g., a stirring vessel, such as a mixing device 36 for mixing the molten glass flowing downstream from the fining vessel 34. The mixing device 36 may be used to provide a homogenous glass melt composition, thereby reducing chemical or thermal inhomogeneities that may be present in the molten glass exiting the fining chamber. As shown, the fining vessel 34 may be coupled to the mixing device 36 via a second connecting conduit 38. In some embodiments, the molten glass 28 may be gravity-fed from the fining vessel 34 to the mixing device 36. For example, gravity may drive the molten glass 28 from the fining vessel 34 to the mixing device 36 through an internal passage in the second connecting conduit 38. Typically, the molten glass in the mixing device 36 includes a free surface, with a free (e.g., gas) volume extending between the free surface and the top of the mixing device. While the mixing device 36 is shown downstream of the fining vessel 34 relative to the flow direction of the molten glass, in other embodiments, the mixing device 36 may be located upstream of the fining vessel 34. In some embodiments, the downstream glass manufacturing equipment 30 can include multiple mixing devices, such as a mixing device upstream from the fining vessel 34 and a mixing device downstream from the fining vessel 34. When multiple mixing devices are used, they can be of the same design or different designs. In some embodiments, one or more of the vessels and / or conduits can include static mixing vanes positioned therein to promote mixing and subsequent homogenization of the molten materials.

[0040] The downstream glass manufacturing apparatus 30 may further include another conditioning chamber, such as a delivery vessel 40 disposed downstream from the mixing apparatus 36. The delivery vessel 40 may condition the molten glass 28 being delivered into the downstream forming apparatus. For example, the delivery vessel 40 may function as an accumulator and / or flow controller to condition and / or provide a consistent flow of the molten glass 28 to the forming body 42 via an outlet conduit 44. In some embodiments, the molten glass in the delivery vessel 40 may include a free surface from which a free volume extends upward to the top of the delivery vessel. As shown, the mixing apparatus 36 may be coupled to the delivery vessel 40 via a third connecting conduit 46. In some examples, the molten glass 28 may be gravity-fed from the mixing apparatus 36 to the delivery vessel 40. For example, gravity may drive the molten glass 28 from the mixing apparatus 36 to the delivery vessel 40 through an internal passage of the third connecting conduit 46.

[0041] The downstream glass manufacturing system 30 can further include a forming apparatus 48 including the aforementioned forming body 42, which includes an inlet conduit 50. The outlet conduit 44 can be positioned to deliver molten glass 28 from the delivery vessel 40 to the inlet conduit 50 of the forming apparatus 48. The forming body 42 in a fusion downdraw glass manufacturing system can include a trough 52 disposed within the upper surface of the forming body and opposing converging forming surfaces 54 that converge in a draw direction 56 along a lower end (root) 58 of the forming body. Molten glass delivered to the forming body trough 52 via the delivery vessel 40, the outlet conduit 44, and the inlet conduit 50 overflows the walls of the trough 52 and descends along the converging forming surfaces 54 as separate streams of molten glass. The separate streams of molten glass merge below and along root 58 to produce a single ribbon of molten glass 60 that is drawn from root 58 in drawing direction 56 by applying downward tension to the glass ribbon, such as by gravity and / or counter-rotating opposing drawing rolls (see FIG. 2 ), which controls the dimensions of the glass ribbon as the molten material cools and the viscosity of the material increases. Thus, glass ribbon 60 undergoes a viscoelastic transition to an elastic state, acquiring mechanical properties that provide glass ribbon 60 with stable dimensional properties.

[0042] To ensure a stable glass forming environment during the forming process, the forming body 42 and at least a portion of the path of travel of the glass ribbon below the forming body may be contained within an open-bottom enclosure 64.

[0043] In some embodiments, the glass ribbon 60 may be separated into individual glass sheets 66 by a glass separator 68. In some embodiments, the glass ribbon may be wound onto a spool and stored for further processing.

[0044] Components of the downstream glass-making equipment 30, including any one or more of the connecting conduits 32, 38, 46, the fining vessel 34, the mixing device 36, the delivery vessel 40, the outlet conduit 44, or the inlet conduit 50, can be formed from precious metals. Suitable precious metals include platinum group metals selected from the group consisting of platinum, iridium, rhodium, osmium, ruthenium, and palladium, or alloys thereof. For example, the downstream components of the glass-making equipment can be formed from a platinum-rhodium alloy containing about 70% to about 90% platinum and about 10% to about 30% rhodium by weight. However, other suitable metals for forming the downstream components of the glass-making equipment can include molybdenum, rhenium, tantalum, titanium, tungsten, and alloys thereof.

[0045] Although the components of the glass manufacturing apparatus 10 are shown and described as fusion downdraw glass manufacturing components, the principles of the present disclosure may be applied to a variety of glass manufacturing processes. For example, melting vessels according to embodiments of the present disclosure may be used in a variety of glass manufacturing processes, such as fusion processes, slot draw processes, rolling processes, pressing processes, float processes, and tube drawing processes.

[0046] To meet production demands, manufacturers have worked to increase the operating capacity and overall lifespan of their glass melting operations. For example, replacing tin electrodes with molybdenum electrodes in the melting vessel increased the interval between electrode changes, which placed additional strain on the lifespan of the melting vessel itself. That is, in conventional installations, the melting vessel typically outlasted the electrodes. Once the electrodes were sufficiently consumed, the melting campaign ended, the melting vessel was rebuilt, and the electrodes were refurbished. As electrode lifespan increased, the lifespan of the melting vessel determined the duration of the melting campaign. Therefore, to prolong a melting campaign, methods to extend the lifespan of the melting vessel are a determining factor in the duration of the campaign.

[0047] 2 and 3 are perspective and top views, respectively, of an exemplary melting vessel 14. As described above, the melting vessel 14 includes a refractory wall, such as multiple stages of precisely cut ceramic bricks or larger blocks. The refractory bricks or blocks are formed from a refractory material such as alumina, zirconia, or another suitable ceramic refractory material. Refractory mortar is optional, and in some embodiments, the melting vessel can be formed without mortar. Typically, the walls of the melting vessel can include a first side wall 100, a second side wall 102, a rear wall 104, a front wall 106, a floor or bottom wall 108 (see FIG. 3), and a roof structure, such as an arched roof structure resting on the walls, which covers the interior volume of the melting vessel formed by the walls, bottom wall, and roof structure. Specifically, the melting vessel can include a lower wall portion that forms an enclosure or pool 110 for holding raw materials that, when melted, form molten glass 28. These walls directly contact the molten glass and therefore can be referred to as glass-contacting walls. Additionally, the various refractory walls of the melting vessel may include an upper wall portion that forms a superstructure on the lower wall portion.

[0048] In various embodiments, the upper wall portion can be separated from the lower wall portion by one or more steel members 112 configured to withstand the weight of the upper wall portion and roof structure. For purposes of explanation and not limitation, the lower wall portion will be referred to below as including a first lower sidewall 100a, a second lower sidewall 102a, a lower rear wall 104a, and a lower front wall 106a. The lower wall portion is disposed on a bottom wall 108. The walls of the superstructure will be referred to below as a first upper sidewall 100b on the first lower sidewall 100a, a second upper sidewall 102b on the second lower sidewall 102a, an upper rear wall 104b on the lower rear wall 104a, and an upper front wall 106b on the lower front wall 106a. A roof or ceiling, hereinafter referred to as a crown 114, is disposed on and supported by the upper side walls 100b, 102b and the upper rear and front walls 104b, 106b, respectively. The crown 114 may also be constructed from firebrick or block. The firebrick or block of the crown 114 may be formed into an arch shape using traditional masonry techniques for forming arches and / or vaults.

[0049] According to some embodiments, as shown in FIG. 2, first and second lower sidewalls 100a, 102a may include openings 116 to accommodate a plurality of electrodes 118 that extend through the openings 116 and into the molten glass 28. The electrodes 118 are supplied with an electrical current that flows through the molten glass to heat it. However, in various other embodiments, the electrodes 118 may instead extend through openings in the bottom wall 108 into the molten glass surrounded by a refractory glass contact wall, as shown in FIG. 3. In various embodiments, the electrodes 118 may include tin (e.g., tin oxide) or molybdenum.

[0050] The upper sidewalls 100b, 102b may include openings 120 that accommodate fuel-oxy burners 122. The fuel-oxy burners may be used to perform initial melting of the batch materials during the start of a melting campaign and to maintain a predetermined temperature or temperature range within the gas volume enclosed by the superstructure above the molten glass 28 during normal melting operations.

[0051] The upper rear wall 104b includes one or more openings 124 configured to receive batch material from the feedstock delivery device 20 through which the raw materials enter the pool 110, while the lower front wall 106a includes a connecting conduit 32 through which the molten glass in the melting vessel 14 can pass as it travels to downstream process equipment, such as the downstream glass manufacturing apparatus 30.

[0052] The melting vessel 14 can be surrounded by a cage of structural members, such as an exoskeleton 125, which helps support the weight of the melting vessel and provide rigidity to the fire-resistant structure. Metal grid panels, such as steel grid panels, can be pressed against the first and second lower side walls, the lower front wall, and / or the lower rear wall by adjustable pressure bolts coupled to the building structural members or to structural members of the exoskeleton (see FIG. 5), and the pressure bolts can engage the metal grid panels via pads between the grid panels and the pressure bolts. The metal grid panels provide a counterforce against the lower side walls, the lower front wall, and the lower rear wall designed to counter the outward pressure exerted by the molten glass against the interior of the walls.

[0053] According to embodiments of the present disclosure, the melting vessel 14 may further include cooling panels having passages through which a cooling fluid may flow to cool one or more of the lower melting vessel walls. In addition to cooling the melting vessel walls, such as the fire-resistant glass contact surface, the cooling panels may also serve a structural function by reinforcing the refractory material used to construct the melting vessel, similar to steel grid panels.

[0054] FIG. 5 shows a portion of a first lower sidewall 100a. The first lower sidewall 100a includes one or more metal grid panels 128 disposed against the first lower sidewall and held in place using a combination of pressure bolts 130 and bracing members 132 (see FIG. 5). The bracing members 132 are attached to one or both of an upper cross member 134 and / or a lower cross member 136, such as by bolts or other suitable fasteners. In some embodiments, the bracing members 132 can be welded to the cross members. The bracing members 132, the upper cross member 134, and / or the lower cross member 136 can be part of or attached to a building structure, such as building structural steel, or can be part of or attached to a melting vessel exoskeleton.

[0055] The pressure bolts 130 are coupled to the bracing members 132 and press against the metal grid panels 128, thereby forcing the metal grid panels against the melter vessel wall. For example, in various embodiments, the pressure bolts 130 include external threads and are coupled to the bracing members via threaded fasteners, such as nuts. This coupling can be achieved by providing a flange 138 extending outward from the bracing members 132 that is attached to the bracing members, for example, by welding. The flange can include an aperture through which the threaded pressure bolts 130 pass. A pair of nuts 140, 142 (see FIG. 8 ) threaded onto the pressure bolts on either side of the flange 138 secure the pressure bolts to the flanges and the bracing members. The pressure on the metal grid panel 128 can be varied by adjusting nuts 140, 142 on the pressure bolts 130 to advance the pressure bolts toward or retract them away from the first lower sidewall 100a, thereby applying or easing pressure against the cooling panel and first lower sidewall. Each pressure bolt can include an engagement foot 144 positioned between the bolt and the metal grid panel to increase the surface area over which the pressure bolt acts on the metal grid panel. The engagement foot can be connected to the pressure bolt by a ball joint or similar, which allows the engagement foot to self-orient (self-level) with respect to the metal grid panel and can account for any irregularities in the surface of the metal grid panel or melting vessel wall. That is, the engagement foot can accommodate an angular offset, such as when the longitudinal axis of the pressure bolt is not perpendicular to the metal grid panel due to slight misalignment of the refractory blocks that make up the melting vessel. Because the refractory material of the melting vessel 14 is electrically conductive and electrical energy is used to heat the molten material contained therein, electrical insulation material 145 may be disposed between each pressure bolt engagement foot 144 and the metal grid panel 128 to electrically insulate the melting vessel and metal grid panel from surrounding metal support members, such as the exoskeleton and / or building steel, that could become energized and pose a safety hazard to personnel.

[0056] In some embodiments, the upper cross-member 134 and / or the lower cross-member 136 can include flanges and pressure bolts to maintain the metal grid panel in contact with the first lower wall 100a.

[0057] According to embodiments disclosed herein, as shown in FIG. 5 , the melting vessel further includes one or more cooling panels 200. Each cooling panel 200 can be positioned against a wall of the melting vessel, such as the first lower sidewall 100 a shown in FIG. 5 , using pressure bolts 130, engagement feet 144, and electrical insulation material 145, similar to the metal grid panel 128, to electrically isolate the melting vessel and cooling panel from surrounding metal support members, such as bracing members 132. That is, the cooling panel 200 is positioned between a melting vessel wall, such as the first lower sidewall 100 a, and one or more pressure bolts 130. The pressure bolts are coupled to the bracing members 132, and can be adjusted by advancing or retracting the pressure bolts 130 relative to the bracing members to apply sufficient pressure to the cooling panel to maintain the cooling panel in contact with the melting vessel wall and / or to counteract the force of molten glass on the other side of the wall.

[0058] 6-8 illustrate an exemplary cooling panel 200. The cooling panel 200 includes a base portion 202 and a cover portion 204. In some embodiments, the base portion 202 and the cover portion 204 may be permanently attached, such as by welding. However, in further embodiments, the cover portion 204 may be configured to be removably secured to the base portion 202 using suitable fasteners 205 (e.g., bolts, screws). A gasket 208 may be disposed between the base portion 202 and the cover portion 204 to prevent leakage. The base portion 202 and / or the cover portion 204 may be formed from a high-temperature, corrosion-resistant material, such as stainless steel.

[0059] 7 is a top view of the base portion 202 with the cover portion 204 removed, showing the internal cooling passage 210 extending within the base portion 202 between an inlet port 212 and an outlet port 214 (see FIG. 8 ) located on the cover portion 204. That is, the cooling passage 210 extends in a zigzag manner from a location within the base portion 202 opposite the inlet port 212 to a termination location within the base portion 202 opposite the outlet port 214 when the cover portion 204 is attached to the base portion 202. The cooling passage 210 may be a separate cooling element located within the cooling panel, such as, for example, a stainless steel tube coupled to the inlet port 212 and the outlet port 214. However, in further embodiments, the internal cooling passage 210 may be machined into either the base portion 202 or the cover portion 204 such that the internal cooling passage 210 is integral with the cooling panel 200 (e.g., the base portion 202). In the illustrated embodiment, cooling passages 210 are milled into base portion 202, leaving a plurality of walls 216 (e.g., baffles) extending alternately from opposing inner sidewalls of the base portion. The walls 216 are positioned to extend beyond a central axis 218 of the base or cover portion, such that the interior cooling passages 210 thus formed are serpentine (e.g., zigzag) in shape to increase the cooling capacity of cooling panel 200 by increasing the length of the cooling passage through which cooling fluid 220 flows. To reduce corrosion, the base and cover portions of the cooling panel may be formed from stainless steel or other high-temperature, corrosion-resistant material.

[0060] In various embodiments, the cooling panel 200 can include one or more monitoring ports 222 for monitoring parameters of the cooling fluid. For example, the cooling panel 200 can have a monitoring device 224 (e.g., a thermocouple, see FIG. 9 ) inserted therethrough. In some embodiments, the monitoring port 222 can extend through the entire thickness of the cover portion 204 or the base portion 202 to allow the monitoring device 224 to be inserted in contact with the cooling fluid 220 flowing within the cooling passages 210. Alternatively, the monitoring port can be located on a side of the base portion 202. The one or more monitoring devices 224 can be in electrical communication with a process controller or other suitable control device (not shown) configured to regulate the temperature and / or flow rate of the cooling fluid through the cooling panel.

[0061] In various embodiments, cooling fluid 220 can be water, while in other embodiments, cooling fluid 220 can be a gas such as air. In some embodiments, the cooling panel can include an open-circuit cooling system in which cooling fluid 220 is supplied from a municipal source, such as a municipal water supply, flows through the cooling panel along cooling passages 210, and is then discarded as waste. However, in other embodiments, the cooling panel can include a closed-circuit cooling system in which cooling fluid, such as water, is circulated between external heat exchangers that provide chilled cooling fluid. The chilled cooling fluid 220 is pumped through the cooling panel, such as by one or more cooling fluid pumps. The now-heated cooling fluid is then circulated from the cooling panel through a heat exchanger to be cooled again and returned to the cooling panel or another process facility.

[0062] In some embodiments, cooling fluid 220 can be routed to and from multiple cooling panels simultaneously through suitable inlet and outlet headers. The cooling fluid lines to and from each cooling panel can be equipped with manual or remotely operated valves to allow isolation of a particular cooling panel, for example, in the event of a leak or if the cooling panel must be removed or replaced. For example, FIG. 5 illustrates cooling panels arranged in pairs (two pairs shown), with each cooling panel 200 in the pair being supplied with cooling fluid from a cooling fluid supply header 226 that supplies cooling fluid to both cooling panels through individual supply lines 228 extending between the supply header 226 and the inlet port 212 of the respective cooling panel. Each supply line 228 can be equipped with an isolation valve 230 positioned to shut off the flow of cooling fluid to the respective cooling panel. The supply header 226 is supplied with cooling fluid 220 through a main supply line 231.

[0063] Additionally, each cooling panel 200 of the cooling panel pair includes an individual return line 232 extending between each cooling panel's respective outlet port 214 and a return header 234. The return header 234 can be placed in fluid communication with a downstream collection device (not shown) through a main return line 236, which can process the cooling fluid, for example, for resupply to the cooling panel. For example, the collection device can process the cooling fluid by filtering the cooling fluid, cooling the cooling fluid, or adding one or more conditioning additives (e.g., corrosion inhibitors). In some embodiments, heat can be extracted from the heated cooling fluid after it leaves the cooling panel, for example, in a heat exchanger, and the extracted heat can be used in further processes. As with the cooling fluid supply, each return line 232 can include an isolation valve 230 configured to shut off the flow of cooling fluid returning from its respective cooling panel. Thus, if necessary, for example, if one of the cooling panels develops a leak, the leaking cooling panel can be isolated by closing the associated shut-off valves in the supply and return lines and removing the problem cooling panel without having to stop the flow of other cooling panels connected to the same supply and return headers. The isolation valves can be manual or remotely operated isolation valves.

[0064] One or more cooling panels 200 may be provided on any one or more of the lower walls of the melting vessel 14, including the lower sidewall, the lower front wall, or the lower rear wall. The modular design of the individual metal grate panels 128 and cooling panels 200 allows for selected grates to be replaced with alternative grates, or cooling panels as needed, during operation of the glass making apparatus, i.e., while the melting vessel is in operation and molten glass is actively forming. To aid in installation of the cooling panels, the cooling panels, for example, the cover portion 204, may include one or more handles 238.

[0065] As shown in FIG. 9 , the cooling panels 200 can be positioned in direct contact with at least one of the first or second lower sidewalls 100 a or 102 a, the lower rear wall 204 a, or the lower front wall 206 a. The metal grid panels 128 are not positioned between the cooling panels 200 and the respective refractory walls or on top of the cooling panels. Thus, the cooling panels 200 function both as cooling devices and as reinforcing members for the respective refractory walls. In various embodiments, one or more metal grid panels 128 and one or more cooling panels 200 can be used to support the lower wall of the melting vessel 14.

[0066] In some embodiments, as best seen in FIG. 6 , the base portion 202 can include a recess 240 disposed on a back surface 242 (the surface that contacts the melting vessel wall). For example, a conformable thermally conductive material 244, such as a compressible metal mesh material, e.g., expanded metal mesh, can be disposed within the recess 240 and sandwiched between the cooling panel and the melting vessel wall. The conformable thermally conductive material 244 can enhance thermal conduction between the cooling panel and the melting vessel wall by providing sufficient flexibility to conform to the melting vessel wall. The conformable thermally conductive material 244 can have an initial thickness greater than the depth of the recess 240, such that when the cooling panel 200 is placed against the melting vessel wall and pressed against the melting vessel wall by the pressure of one or more pressure bolts, the conformable thermally conductive material 244 is compressed and conforms to the shape of the melting vessel wall.

[0067] Each cooling panel 200 may be positioned such that the flow of cooling fluid 220 through the cooling panel is upward, counter to gravity, to complement the cooling fluid's natural tendency to move upward upon heating (due to heat exchange with the hot refractory wall) and to prevent the formation of stagnant bubbles in the cooling passages 210. However, in further embodiments, the flow of cooling fluid may be downward. For example, in some embodiments, the input port 212 may be located in the upper half of the cooling panel and the outlet port 214 may be located in the lower half of the cooling panel. In yet another embodiment, the input port 212 may be located at or adjacent a first side edge of the cooling panel and the outlet port 214 may be located at or adjacent a second side edge opposite the first side edge of the cooling panel, such that the flow of cooling fluid is directed laterally from the first side to the second side of the cooling panel.

[0068] As described above, each cooling panel 200 can be held in place against the lower refractory wall by one or more pressure bolts 130 that engage the cooling panel 200 and brace member 132, each extending between the brace member 132 and an engagement foot 144 that contacts the cooling panel. Pressure can be applied to the engagement foot 144 and cooling panel 200 by loosening the first outer nut 140 (rotating the first nut 140 away from the brace member 132 and cooling panel), then rotating the second inner nut 142 relative to the brace member 132 until the desired pressure against the cooling panel 200 is achieved, and then rotating the first nut 140 until it is tight against the brace member 132. Additionally or alternatively, the pressure bolts can include spring elements to provide flexibility in the connection between the cooling panel and the brace member. For example, in some embodiments, pressure bolts 300 can be used. FIG. 10 schematically illustrates an exemplary pressure bolt 300. The pressure bolt 300 generally includes a threaded rod 302 extending through a body 304. The body 304 includes a plurality of Belleville washers 306, such as Belleville washers, that bias the threaded rod 302 in the direction indicated by arrow 308. A first end of the threaded rod 302 includes a tensioning nut 310, and a second end of the threaded rod 302 includes an engagement foot 312. The pressure bolt 300 may also include a jam nut 314 disposed on the threaded rod 302 that is advanceable against the body 304 to prevent compression of the Belleville springs 306. The pressure bolt 300 may be coupled to the brace member 132 in a manner similar to the pressure bolt 130.

[0069] It will be apparent to those skilled in the art that various modifications and variations can be made to the embodiments of the present disclosure without departing from the spirit and scope of the disclosure. Accordingly, the present disclosure is intended to cover all such modifications and variations, provided they come within the scope of the appended claims and their equivalents. [Explanation of symbols]

[0070] 14 Melting vessel 32 First connecting conduit 100a First lower sidewall 128 Metal Grid Panel 130 pressure volts 132 Bracing members 134 Upper cross member 136 Lower cross member 138 flange 144 Engagement feet 200 cooling panel 212 Inlet Port 214 Exit Port 220 Cooling fluid 226 Supply Header 228 Supply Line 230 Shut-off valve 231 Main Supply Line 232 Return Line 234 Return Header 236 Main return line

Claims

1. 1. A glass manufacturing apparatus comprising: a melting vessel including a refractory glass contact wall; an exoskeleton including an upper cross member, a lower cross member, and first and second bracing members attached to the upper and lower cross members, wherein the melt vessel is enclosed within the exoskeleton; an exoskeleton in which a metal grid panel contacts the fire-resistant glass contact wall and is urged against the fire-resistant glass contact wall by a first pressure bolt, the first pressure bolt being coupled to the first brace member and pressing against the metal grid panel, and the pressure on the metal grid panel being variable by adjusting the first pressure bolt; a cooling panel configured to receive a cooling fluid through an inlet port and to discharge the cooling fluid through an outlet port; the cooling panel is in contact with the fire-resistant glass contact wall and is urged against the fire-resistant glass contact wall by a second pressure bolt, the second pressure bolt being coupled to the second brace member and pressing against the cooling panel, and the pressure on the cooling panel is variable by adjusting the second pressure bolt. A glass manufacturing apparatus characterized by:

2. the inlet port is located in a lower half of the cooling panel and the outlet port is located in an upper half of the cooling panel. The glass manufacturing apparatus according to claim 1 .

3. the refractory glass contact wall comprises a side wall of the melting vessel; The glass manufacturing apparatus according to claim 1 .

4. the cooling panel including a serpentine passage extending within the cooling panel between the inlet port and the outlet port. The glass manufacturing apparatus according to claim 1 .

5. the cooling panel includes a base portion and a cover portion, the serpentine passage being machined into the base portion, and the cover portion being attached to the base portion. The glass manufacturing apparatus according to claim 4.

6. the base portion contacts the fire-resistant glass contact wall; The glass manufacturing apparatus according to claim 5 .

7. the base portion includes a back surface including a recess formed therein, and a compatible thermally conductive material is disposed within the recess between the cooling panel and the fire-resistant glass contact wall. The glass manufacturing apparatus according to claim 6.

8. The melting vessel includes a second metal grid panel in contact with and biased against the fire-resistant glass contact wall, the second metal grid panel being positioned below the cooling panel. The glass manufacturing apparatus according to claim 1 .

9. the melting vessel includes a third metal grid panel in contact with and biased against the fire-resistant glass contact wall, the third metal grid panel being positioned above the cooling panel; The glass manufacturing apparatus according to claim 8.

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