Flow block for use in glass manufacturing and corresponding method

Abstract

Systems and method of reducing corrosion within a glass manufacturing apparatus are provided herein. The glass manufacturing apparatus comprises a melting vessel having a flow block assembly which provides a conduit between an inside volume and downstream process. The flow block assembly comprises at least one refractory brick defining an exterior side for facing away from an inside volume of the refractory and an interior side for facing toward the inside volume of the refractory. At least a portion of the interior side comprises a cladding formed from a corrosion resistant cladding material. The flow block assembly further comprises a tube defining an interior end and an opposite exterior end disposed through the at least one refractory brick such that the interior end extends beyond the interior side of the at least one refractory brick, and the exterior end extends beyond the exterior side.

Description

FLOW BLOCK FOR USE IN GLASS MANUFACTURING AND CORRESPONDING METHODCROSS-REFERENCE TO RELATED APPLICATION

[0001] This application claims the benefit of priority under 35 U.S.C. § 119 of U.S. Provisional Application Serial No. 63 / 666801 filed on July 2, 2024, the content of which is relied upon and incorporated herein by reference in its entirety.FIELD

[0002] Embodiments herein relate generally to glass manufacturing, and more particularly to assemblies, systems, and methods for extending the lifespan of refractories and maintaining glass quality, such as by reducing corrosion within the glass manufacturing process.BACKGROUND

[0003] Optical quality glass sheets are commonly employed in a variety of optical display devices including LCD displays, LED displays, and the like. Various manufacturing processes may be used to produce the optical quality glass sheets. These manufacturing processes generally involve melting glass precursor materials in ceramic refractory furnaces, and then producing a ribbon of glass from the glass melt by drawing the glass melt from a forming body. Individual glass sheets are then cut from the ribbon of glass.

[0004] During the manufacturing process, the refractory surfaces come into contact with molten glass. The molten glass is corrosive due to the high temperature and nature of the material. Corrosion within the refractory bricks causes the refractory brick to thin, thereby increasing the thermal conductivity thereof. Due to the corrosion, the temperature of the molten glass within the refractory decreases, which increases the burden on the downstream process to maintain desired temperature and quality - and may impact the quality of the glass sheets being formed. Thus, there exists a need to decrease the corrosion of the refractory walls during the melting process, such as to reduce flaws in the product and / or extend the useful lifespan of the refractory and / or its components.BRIEF SUMMARY

[0005] Embodiments of the present disclosure are directed towards assemblies, systems, and methods for glass manufacturing. In some embodiments, a flow block assembly for a refractory within the glass manufacturing process is provided. Such a flow block assembly may include cladding disposed about an interior surface of the refractory brick forming the flow block of the melting refractory. The cladding may be attached to a refractory melting vessel exit tube which extends through the thickness of the refractory brick between the inside volume of the refractory (which holds the molten glass) and the downstream processes. The assembly may additionally include a flange positioned on an exterior surface of the refractory brick, which is radially spaced apart from and adjacent to the refractory melting vessel exit tube.

[0006] The cladding prevents corrosion of the underlying refractory brick, and thereby maintains the thickness of the refractory brick and thermal conductivity - increasing the useful life of the flow block assembly (and the overall refractory) and maintaining glass quality during the glass manufacturing process.

[0007] In an example embodiment a glass manufacturing apparatus is provided. The glass manufacturing apparatus comprises a flow block assembly. The flow block assembly comprises at least one refractory brick, The at least one refractory brick comprises an exterior side for facing away from an inside volume of the refractory and an interior side for facing toward the inside volume of the refractory. At least a portion of the interior side comprises a cladding formed from a cladding material. The cladding material is corrosion resistant. The glass manufacturing apparatus further comprises a tube disposed through the at least one refractory brick. The tube defines an interior end and an opposite exterior end. The interior end extends beyond the interior side of the at least one refractory brick, and the exterior end extends beyond the exterior side of the at least one refractory brick.

[0008] In some embodiments, the cladding material may comprise a platinum alloy. In some embodiments, the cladding material may comprise platinum and rhodium. In some embodiments, the cladding may define a cladding thickness between 1 - 1.5 mm.

[0009] In some embodiments, the tube may comprise a first section adjacent the interior end and a second section adjacent the exterior end. In some embodiments, the first section may be crimped. In some embodiments, the second section is smooth. In some embodiments, the tube may further comprise a tube flange extending from the tube proximate the exterior end. In some embodiments, the tube may be welded to the cladding.

[0010] In some embodiments, the glass manufacturing apparatus may further comprise a flange defining a front face and an opposite rear face. The rear face may be disposed on the exterior side of the at least one refractory brick, and the flange may be radially spaced apart from the exterior end of the tube.

[0011] In some embodiments, the at least one refractory brick may further comprise a first side and an opposite second side. The cladding may extend to each of the first side and the second side. In some embodiments, the cladding may define a side edge profile at a juncture between a back face of the cladding and a first side of the cladding, and between the back face of the cladding and a second side of the cladding. The side edge profile may define a fillet. In some embodiments, the fillet may be greater than 1 / 8 inch.

[0012] In another example embodiment a melting vessel for holding molten glass is provided. The melting vessel comprises a plurality of walls comprising at least one front wall, the front wall comprising a flow block assembly. The flow block assembly comprises at least one refractory brick, The at least one refractory brick comprises an exterior side for facing away from an inside volume of the refractory and an interior side for facing toward the inside volume of the refractory. At least a portion of the interior side comprises a cladding formed from a cladding material. The cladding material is corrosion resistant. The flow block assembly further comprises a tube disposed through the at least one refractory brick. The tube defines an interior end and an opposite exterior end. The interior end extends beyond the interior side of the at least one refractory brick, and the exterior end extends beyond the exterior side of the at least one refractory brick.

[0013] In some embodiments, the cladding material may comprise a platinum alloy. In some embodiments, the cladding material may comprise platinum and rhodium. In some embodiments, the cladding may define a cladding thickness between 1 - 1.5 mm.

[0014] In some embodiments, the tube may comprise a first section adjacent the interior end and a second section adjacent the exterior end. In some embodiments, the first section may be crimped. In some embodiments, the second section is smooth. In some embodiments, the tube may be welded to the cladding.

[0015] In some embodiments, the melting vessel may further comprise a flange defining a front face and an opposite rear face. The rear face may be disposed on the exterior side of the at least one refractory brick, and the flange may be radially spaced apart from the exterior end of the tube.

[0016] In some embodiments, the at least one refractory brick may comprise a first side and an opposite second side. The cladding may extend to each of the first side and the secondside. In some embodiments, the cladding may define a side edge profile at a juncture between a back face of the cladding and a first side of the cladding, and between the back face of the cladding and a second side of the cladding. The side edge profile may define a fillet.

[0017] In yet another example embodiment a method of mitigating temperature drop within an melting vessel is provided. The method comprises providing a melting vessel bound by a plurality of walls, comprising at least one flow block assembly. The flow block assembly comprises at least one refractory brick, The at least one refractory brick comprises an exterior side for facing away from an inside volume of the refractory and an interior side for facing toward the inside volume of the refractory. At least a portion of the interior side comprises a cladding formed from a cladding material. The cladding material is corrosion resistant. The flow block assembly further comprises a tube disposed through the at least one refractory brick. The tube defines an interior end and an opposite exterior end. The interior end extends beyond the interior side of the at least one refractory brick, and the exterior end extends beyond the exterior side of the at least one refractory brick. The method further comprises providing molten glass to the melting vessel.BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING(S)

[0018] Reference will now be made to the accompanying drawings, which are not drawn to scale, and wherein:

[0019] FIG. 1A illustrates a perspective view of an example refractory, in accordance with some examples discussed herein;

[0020] FIG. IB illustrates a top view of an example refractory, in accordance with some embodiments discussed herein;

[0021] FIG. 2A illustrates an internal view of an example flow block assembly and corrosion surrounding the flow block, as discussed herein;

[0022] FIG. 2B illustrates an internal view of another example flow block and corrosion surrounding the flow block, as discussed herein;

[0023] FIG. 3A illustrates a perspective view of an exterior side of an example flow block assembly, in accordance with some embodiments discussed herein;

[0024] FIG. 3B illustrates a perspective view of an interior side of an example flow block assembly, in accordance with some embodiments discussed herein;

[0025] FIG. 4 illustrates a perspective view of example cladding positionable on refractory brick, in accordance with some embodiments discussed herein;

[0026] FIG. 5 illustrates a side perspective view of the cladding edges, in accordance with some embodiments discussed herein;

[0027] FIG. 6 illustrates a cross-sectional view of the flow block assembly shown in FIG. 3B taken along line A-A, in accordance with some embodiments discussed herein;

[0028] FIG. 7 illustrates a cross-sectional view of the refractory melting vessel exit tube, in accordance with some embodiments discussed herein;

[0029] FIG. 8A illustrates a cross-sectional perspective view of the interface between a refractory melting vessel exit tube and a flange, in accordance with some embodiments discussed herein;

[0030] FIG. 8B illustrates a cross-sectional view of the interface between a refractory melting vessel exit tube and the flange and an adjacent refractory brick, in accordance with some embodiments discussed herein; and

[0031] FIG. 9 illustrates a flow chart of example methods of forming a refractory, in accordance with some embodiments discussed herein.DETAILED DESCRIPTION

[0032] Some example embodiments will not be described more fully herein with reference to the accompanying drawings, in which some, but not all example embodiments are shown. Indeed, the examples described and pictured herein should not be construed as being limiting to the scope, applicability or configuration of the present disclosure. Rather, these example embodiments are provided so that this disclosure will satisfy applicable legal requirements. Like reference numerals refer to like elements throughout.

[0033] Directional terms as used herein- for example, up, down, left, right, front, back, top, bottom, vertical, and horizontal - are made only with reference to the figures as drawn and are not intended to imply absolute orientation.

[0034] FIG. 1A illustrates a perspective view of an example melting vessel (e.g., a refractory melting vessel) 100. As used herein the term “melting vessel” may mean a refractory melting vessel, a melting furnace, or similar. The melting vessel 100 comprises an inside volume 102 which receives raw materials and converts the raw material into a molten glass. The inside volume 102 is bound by a front wall 109, a first side wall 108a, a second side wall 108b, and a rear wall 108c (and typically a bottom wall and top wall - not shown). Each of the front wall 109, the first side wall 108a, the second side wall 108b, and the rear wall 108c comprise one or more refractory bricks 104 (shown in FIG. IB). With reference to FIG. IB, the frontwall 109 defines a flow block 110 which provides a conduit for the molten glass to exit the inside volume 102 and flow to downstream processes within the glass manufacturing process.

[0035] The one or more refractory bricks 104 may be a ceramic material. In some embodiments, the refractory brick 104 may be a fused cast refractory material. In some embodiments, the refractory brick 104 may be a material comprising alumina or zirconia, although the refractory ceramic material can comprise other refractory materials, such as yttrium (e.g., yttria, yttria-stabilized zirconia, yttrium phosphate), zircon (ZrSiO4) or alumina-zirconia-silica or even chrome oxide, used either alternatively or in any combination.

[0036] In some embodiments, the refractory brick 104 may contact the molten glass, and may corrode over time. When the refractory brick 104 corrodes, the material thickness thins, which increases thermal conductivity, and in turn, lowers the temperature of the molten glass substance within the inside volume 102 and / or flowing past the adjacent compromised refractory brick. The thinning of the refractory brick 104 is especially of concern about the flow block 110 where the molten glass exits the inside volume 102 and flows to downstream processes.

[0037] FIGs. 2A-B illustrate the interior surface of two flow blocks illustration corrosion due to contact with molten glass. FIG. 2A illustrates a first flow block 200a exhibiting a corroded refractory brick 205 extending about a tube 232, and a flange 240 extending from the tube 232. The corroded refractory brick 205 is corroded away from both the tube 232 and the flange 240 extending therefrom. The illustrated embodiment shows a corrosion wear of 6.5”. FIG. 2B illustrates a second flow block 200b exhibiting corrosion refractory brick 205 surrounding the tube 232 and flange 240 attached thereto. The illustrated embodiments shows a corrosion wear of 4.5”.

[0038] In each of these examples, there was no cladding around the flow block, the front wall, the side walls, the back wall, or otherwise disposed within the interior area 102 of the melting vessel. Thus, the refractory brick was exposed to the elevated temperatures of the molten glass and brought into contact therewith, which caused the refractory brick to corrode. As the refractory brick corrodes there is less thickness separating the molten glass from the exterior of the melting vessel. Further, as the corrosion progresses there may be leaks of gasses produced in the melting vessel, or even leaks of the molten glass through the refractory brick. Further, since the refractory brick is no longer insulated with the thickness of the refractory brick, heat may escape thought the refractory brick, and may lower the temperature. As the refractory brick thins, the thermal conductivity of the refractory brick increases, which in turn lowers the temperature of the glass. Thus, to maintain the requisitetemperature of the glass exiting through the tube 232 methods and operations to reduce and / or slow the corrosion of the refractory brick may be implemented.

[0039] Returning to FIG. IB, to reduce the corrosion of the refractory brick, cladding may be applied to the flow block, as illustrated. In other embodiments, cladding 120 may be applied across the interior surface of each of the front wall 109, the first side wall 108a, the second side wall 108b, and the rear wall 108c. The cladding 120 may prevent corrosion and minimize the phenomenon of temperature decrease, which decreases the burden on downstream systems.

[0040] FIGs. 3A-B illustrate the front wall 109 of the melting vessel 100 comprising a flow block assembly 110 wherein the refractory brick 104 of the flow block assembly 110 comprises cladding 120 applied thereto.

[0041] FIG. 3A illustrates a perspective view of the exterior side of a portion of the front wall109 of the melting vessel 100. The front wall 109 may comprise a number of refractory bricks 104 positioned adjacent one another and on top of one another. A flow block assembly110 may be one of the segments of the front wall 109 which provides a conduit for the contents of the inside volume to flow through the refractory brick 104 downstream for further processing.

[0042] In some embodiments, the flow block assembly 110 may comprise a tube 132 extending between the inside volume to the downstream process. Because of the high temperatures and the corrosive nature of molten glass, the tube 132 may be formed from temperature and corrosion resistant metals. In this regard, corrosion resistant materials are able to withstand contact with the molten glass and the melting vessel temperatures without degradation or a change in the properties of the material. In some embodiments, the tube 132 may be platinum.

[0043] The exterior side of the flow block assembly 110 may include a flange 140 extending about the tube 132. In some embodiments, the flange 140 may comprise a circumferential surface 146 which is radially spaced apart from the tube 132. In some embodiments, the flange 140 may provide an electrical current to the circumferential surface 146. In this regard, the flange 140 may be provided with an electrical current which travels through the flange 140 and heats the circumferential surface 146 through Joule heating. Such Joule heating can, for example, assist in controlling the viscosity of the molten glass in preparation for downstream forming processes.

[0044] The flow block assembly 110, may further include cladding 120 about the refractory brick (not shown). In some embodiments, the cladding 120 may comprise a temperature andcorrosion resistant metal. In some embodiments, the cladding 120 may be formed of a platinum alloy. The cladding material may comprise at least 80% platinum by weight, preferably at least 85% platinum by weight, and more preferably may comprise at least 90% platinum by weight.

[0045] In some embodiments, the platinum alloy may be a mixture of platinum and another platinum family metal including rhodium, palladium, iridium, osmium, and ruthenium.

[0046] FIG. 3B illustrates, a perspective view of the interior side of the front wall 109, specifically illustrating the positioning of the cladding 120 on the interior side of the flow block assembly 110. The cladding 120 may be positioned on the refractory brick 104 such as to cover the surface of the refractory brick adjacent to and supporting the tube 132. The refractory brick in this area may be especially susceptible to corrosion due to the constant contact with molten glass. In order to reduce the corrosion, the cladding 120 may be applied to the refractory bricks. To prevent glass from penetrating the refractory brick at the interface between the cladding 120 and the tube 132, the cladding 120 may be welded to the tube 132.

[0047] In some embodiments, the cladding 120 may be positioned below the glass line, and thus, does not extend to the top of the front wall 109, or other walls of the refractory 100. Positioning the cladding 120 below the glass line prevents oxidation of the platinum at the glass line. Oxidation of the platinum may cause the cladding to be more easily tom during operation and may disconnect and clog the tube 132.

[0048] FIG. 4 illustrates the footprint of the cladding 120 applied to the refractory brick. In some embodiments, the cladding 120 may comprise a back face 124 which may be applied to the interior side of the refractory brick, and a first side 122a and a second side 122b each which may be applied to a first side of the refractory brick and a second side of the refractory brick respectfully, wherein the first side of the refractory brick and the second side of the refractory brick define an interface between the flow block (e.g., 110 FIG. 3B) and an adjacent refractory brick (e.g., 104 FIG. 3B). In some embodiments, the cladding 120 may also have a top edge 121 applied to a top side of the refractory brick of the flow block assembly 110. In some embodiments, an additional support 123 may be applied between the first side 122a and the second side 122b. The additional support 123 may prevent tearing of the cladding and may provide additional strength.

[0049] In some embodiments, an opening 125 may be positioned within the back face 124 of the cladding 120. The opening 125 may be configured to circumscribe the tube 132 and be welded thereto.

[0050] In some embodiments, the cladding 120 may define a cladding height HT. The cladding material may define a failure height which defines a height where without additional support the cladding may creep and tear due to the weight of the cladding, and shear forces from the glass flow within the inside volume and through the tube 132. If the cladding height HT is greater than the failure height, the additional support 123 may be added to the cladding 120 to prevent failure. Notably, the additional support 123 divides the cladding into a first height Hi and a second height H2. Thus, when the first height Hi is greater than the failure height, the additional support 123 may be utilized. In some embodiments, the failure height may be 10 in, 12 in, 14, in, 16 in, or other height which causes tearing and creep due to the weight of the cladding and the shear force of the glass flow on the cladding.

[0051] The first height Hi may be measured between the bottom of the cladding (e.g., the base of the inside volume) to the additional support 123, and the second height H2 may extend from the additional support 123 to the top edge 121. In other embodiments, with reference to FIG. 6, the cladding height HT may further include a third height H3 wherein the third height H3 extends within a refractory brick positioned below the tube 132.

[0052] In some embodiments, the cladding may define a cladding thickness. In some embodiments, the cladding thickness may be between 20-70 mils, between 30-60 mils, or more preferably between 40-50 mils. In some embodiments, the thickness of the cladding may correspond to the height of the cladding. In this regard, when the cladding defines a greater cladding height HT the thickness of the cladding must be optimized for the weight and material properties. When the cladding defines a smaller cladding height HT, the thickness may be reoptimized for the weight.

[0053] In some embodiments, the cladding 120 may define a cladding width Wc. The cladding width length Wc may extend along the width of the refractory brick of the flow block assembly 110. In other embodiments the cladding width Wc may extend across a portion of the front wall, along the entire front wall (e.g., 109 FIG. IB), or even along the first side wall, second side wall, and / or the rear wall (see e.g., 108a, 108b, 108c FIG. 1A). However, the cladding width Wc should not increase the voltage imbalance of the one or more electrodes (107a, 107b) over a threshold amount.

[0054] In some embodiments, the cladding may be designed to reduce strain and stress caused by a coefficient of thermal expansion (CTE) mismatch between the cladding material and the refractory brick. In this regard, the refractory brick exhibits a different expansion profile than the cladding material. The CTE mismatch introduces significant strain to the cladding. With reference to FIG. 5, in order to reduce the strain induced by the CTEmismatch the cladding may comprise a side edge profile 126 at the juncture between the first side 122a and the back face 124, and the second side 122b and the back face 124, and atop edge profile 127 at the juncture between the back face 124 and the top edge 121. Each of the side edge profile 126 and the top edge profile 127 may comprise filets. In this regard, the edge profile may be defined by a rounded edge where the two surfaces meet. The use of the fillet as the side edge profile 126 and the top edge profile 127 reduces the stress and strain due to the CTE mismatch. In some embodiments, the fillet may be a radius of curvature. In some embodiments, the radius of curvature may be greater than 1.5 mm, preferably greater than 2.3 mm and more preferably greater than 3 mm. In some embodiments, the side edge profile 126 and the top edge profile 127 may define the same fillet size, while in other embodiments the top edge profile 127 may define a larger fillet size than the side edge profile 126, and still in other embodiments the top edge profile 127 may define a smaller fillet than the side edge profile 126.

[0055] FIG. 6 illustrates a cross sectional view of the flow block assembly 110, without the refractory brick, and flow apparatus. As discussed, the flow block assembly 110 may comprise refractory brick which is cladded with the cladding material. The refractory brick 104 may define an interior surface 104b which faces the inside volume 102, and an external surface 104a which faces the exterior of the refractory 100. Each refractory brick 104 defines a refractory thickness Ti which corrodes when exposed to molten glass, and the temperatures of the molten glass. As discussed, to reduce the corrosion, and to maintain the refractory thickness Ti about the flow apparatus 130 positioned through the refractory brick 104, the refractory brick of the flow block assembly 110 is cladded with a cladding 120. In this regard, the cladding 120 prevents the underlying refractory brick 104 from corroding, thereby maintain the refractory thickness Ti about the flow apparatus 130.

[0056] In some embodiments, the flow apparatus 130 comprises the tube 132 which extends between an interior end 132b and an exterior end 132a. In some embodiments, the interior end 132b is positioned within the inside volume such that the molten glass may be removed through the interior end 132b and flow through the tube 132 and exit the tube 132 via the exterior end 132a to downstream processing.

[0057] The tube 132 may define a tube length LPMT may extend between the interior end 132b and the exterior end 132a. The tube length LPMF may be greater than the refractory thickness Ti as the tube 132 as the tube 132 extends beyond each of the interior surface 104b and the exterior surface 104a of the refractory brick 104.

[0058] In some embodiments, the cladding 120 of the refractory brick 104 mitigates corrosion to the refractory brick. Since the thickness Ti of the refractory brick 104 is maintained, the tube length LPMT may be decreases in relation to other configurations without the cladding 120.

[0059] With reference to FIG. 7, the tube 132 may comprise a first section 134 and a second section 136. In some embodiments, the first section 134 may extend from the interior end 132a, and the second section 136 may extend from the exterior end 132b. In some embodiments, a tube flange 138 may extend from the second section 136 of the tube. The tube flange 138 may be welded to the second section 136 at a tube weld 139. In some embodiments, the tube weld 139, and the tube flange 138 may extend about the circumference of the second section 136 of the tube.

[0060] In some embodiments, the first section 134 may define a plurality of crimps, wherein the crimps define a varying diameter between a first crimp diameter Dei where the diameter is at a minimum, and a second crimp diameter Dc2 where the diameter is at a maximum. The second section 136 may have an even or regular surface. In this regard, the second section 136 may be free from projections, lumps, or indentations, or may otherwise define a smooth surface. In some embodiments, the second section 136 may define a section diameter Ds. In some embodiments, the section diameter Ds may be about the same as the first crimp diameter Dei, while in other embodiments, the section diameter Ds may be smaller than the first crimp diameter Dei. In some embodiments, the section diameter Ds may be larger than the first crimp diameter Dei and smaller than the second crimp diameter Dc2.

[0061] In some embodiments, the tube flange 138 may define a tube flange diameter DR. In some embodiments, the tube flange diameter DR may be greater than the second crimp diameter Dc2 and the section diameter Ds.

[0062] Returning to FIG. 6, the flow apparatus 130 further comprises, a flange 140 is positioned on the external surface 104a of the refractory brick 104 adjacent the tube 132. The flange 140 may provide a seal to the refractory such that the molten glass is retained within the inside volume unless and until the molten glass is released to downstream production through the flow apparatus 130. In some embodiments, the flange 140 may define a front face 142, and a rear face 144. In order to retain the heat each of the front face 142 and the rear face 144 may be coated with the cladding material.

[0063] As discussed herein, the flange 140 may be separable from the tube 132. In some embodiments, the tube 132 may comprise different sections. In some embodiments, the flange 140 may be removable such that the flange 140 may be replaced as necessary. In thisregard, if the flange 140 develops a flaw (e.g., a leak, etc.) the flange may be removed and replaced. As will be discussed herein, although the flange 140 overlaps the tube 132, the flange 140 and the tube may remain separate and separable units.

[0064] With reference to FIG. 7, the flange 140 defines a circumferential surface 146 which is radially spaced apart from and circumvents the second section 136 of the tube 132. The front face 142 and the rear face 144 may be connected to the circumferential surface 146. In some embodiments, the front face 142 is connected to the circumferential surface 146 at a first weld 152, and the rear face 144 is connected at a second weld 154. In some embodiments, the circumferential surface 146 may extend beyond the first weld 152 and / or the second weld 154. In this regard, the front face 142 and the rear face 144 may not be flush with the ends of the circumferential surface 146 of the flange 140. In some embodiments, each of the front face 142 and the rear face 144 may be cladded with the cladding material.

[0065] In some embodiments, the circumferential surface 146 defines a flange diameter DF. The flange diameter DF may be greater than the section diameter Ds, the first crimp diameter Dei and the second crimp diameter Dc2. The flange diameter DF may be about the same size as the tube flange diameter DR. In this regard, the tube flange 138 may define a similar diameter to the circumferential surface 140a of the flange 140 but may maintain a distance therebetween. Thus, the flange may be removed separate from the tube 132. FIGs. 8A-B illustrate the configuration of the tube flange and the circumferential surface.

[0066] FIGs. 8A-B illustrate perspective views of the flow apparatus 130, wherein the tube 132, specifically the second section 136 is proximate to the flange 140. As illustrated the tube flange 138 may be adjacent to but axially spaced apart from the circumferential surface 146, such that the tube flange 138 does not abut the circumferential surface 146 of the flange 140. In this regard, the tube flange 138 is spaced a first distance Di from the circumferential surface 146. In some embodiments, the first distance Di may be large enough to prevent fusion between the tube flange 138 and the circumferential surface 146. In some embodiments, the first distance Di may be at least 3 mm, at least, at least 5 mm, at least 6 mm. In some embodiments, the first distance Di may be up to 13 mm, up to 9 mm, or even up to 7 mm.

[0067] In some embodiments, the second section 136 may be radially spaced apart from the circumferential surface 146 by a second distance D2. In some embodiments, the second distance D2 may be greater than the first distance Di. In some embodiments, the second distance D2 may provide adequate space between the second section 136 and the circumferential surface 146 to prevent installation, or uninstallation issues.

[0068] As discussed, the addition of the cladding to the refractory brick reduces the corrosion and relieves the burden on downstream processes. However, the cost of applying the cladding to the interior surfaces may be costly for the results produced. For example, in tests, cladding the entire front wall 109 gave the largest temperature drop reduction, followed by the cladding the flow block 110. The additional cladding of the first side wall, and the second side wall, and / or the rear wall only minimally reduced the temperature drop.

[0069] In addition to balancing costs due to the cladding materials, the effect of the cladding on the melting process within the refractory is considered. Returning to FIG. IB, the refractory 100 receives raw material and subjects the raw material to heat to melt the raw materials into the molten glass for further processing. To generate the heat within the inside volume 102 various heating methods may be used, for example, combustion heating, or electrical resistance heating. In some embodiments, the refractory 100 may be electrically boosted such that the energy is added to the raw materials through both combustion burnings, and by direct heating (wherein an electrical current is established through the raw materials to heat the raw material through Joule heating).

[0070] In electrical resistance heating, as illustrated in FIG. IB, one or more electrodes 107a, 107b may be positioned within the inside volume 102 of the refractory 100. In some embodiments, a first electrode 107a and a second electrode 102b may be positioned within the inside volume 102 To engage in Joule heating, a voltage may be applied over a first electrode 107a and a second electrode 107b to drive a current through the raw materials, thereby heating and melting the raw materials. The raw materials may be heated to a desired temperature which is suitable for downstream processing.

[0071] In some embodiments, the cladding 120 may affect the current flow between the first electrode 107a and the second electrode 107b, which in turn creates an undesirable voltage imbalance between the electrodes. In this regard, the current generated by the first electrode 107a and the second electrode 107b may flow towards the cladding 120 on the flow block 110, as the cladding 120 may comprise a conductive material.

[0072] To minimize the current imbalance and maintain current loading to CBT there may be an optimal distance between each electrode and the cladding 120. In some embodiments, the first electrode 107a may be a first electrode distance DEI from the edge of the cladding 120, and the second electrode 107b may be a second electrode distance DE2 from the edge of the cladding 120. In this regard, if either the first electrode distance DEI or the second electrode distance DE2 is too small the current of the corresponding electrode may fire through the cladding 120 rather than the raw materials or molten glass within the inside volume 102.

[0073] The width of the cladding across the flow block assembly 110 directly impacts the voltage imbalance between the first electrode 107a and the second electrode 107b. The voltage imbalance may cause a current imbalance flowing through the electrodes, which may require replacement of a current balancing transfer (CBT); replacement of the electrodes; uneven reactions, which may lead to an unacceptable quality of glass; equipment damage, which may cause firing through the cladding; and may be a safety hazard.

[0074] Further, the difference in the first electrode distance DEI and the second electrode distance DE2 may cause different voltage to fire through the cladding 120. In some embodiments, if there is a voltage difference less than a maximum distance the system will function properly. The first electrode distance DEI and the second electrode distance DE2 influence the voltage imbalance based on the width of the cladding 120. Thus, there may be an optimal placement for each of the first electrode 107a and the second electrode 107b to generate the necessary heat within the system, while maintaining a current balance through the inside volume 102.Example Flowchart! s)

[0075] FIG. 9 is a flowchart illustrating an example method 300 for forming and utilizing a glass making refractory which reduces corrosion and reduces the temperature drop across the flow apparatus. At operation 310, a refractory is provided with at least one flow block assembly. The refractory may be bound by a plurality of walls, wherein the flow block assembly is formed within one of the plurality of walls. The at least one refractory brick of the flow block assembly defines an exterior side facing away from an inside volume of the refractory and an interior side facing towards the inside volume. The refractory may be a melt refractory, a melt furnace or similar. At operation 320, the interior side of the refractory brick is cladded with a cladding material. The cladding material may define a high temperature and corrosion resistance.

[0076] At operation 330, a tube is disposed through the flow block assembly. The tube may defines an interior end and an opposite exterior end. The interior end extends beyond the interior side of the at least one refractory brick, and the exterior end extends beyond the exterior side of the at least one refractory brick. The tube provides a conduit for the materials within the inside volume of the refractory. Optionally at operation 340, a flange is disposed on an exterior side of the flow block. Optionally at operation 350, the flange is cladded. The cladding material may be temperature and corrosion resistant.

[0077] At operation 360 materials may be provided into the inside volume of the refractory. In some embodiments, the materials may be raw materials which may be melted into molten glass, and in other materials the materials may be molten glass.

[0078] Notably, the above operations for FIG. 9, while described in a certain order, may be performed in a different order and / or some of the operations may be performed simultaneously.

[0079] It will therefore be readily understood by those persons skilled in the art that the present disclosure is susceptible of broad utility and application. Many embodiments and adaptations of the present disclosure other than those herein described, as well as many variations, modifications and equivalent arrangements, will be apparent from or reasonably suggested by the present disclosure and the foregoing description thereof, without departing from the substance or scope of the present disclosure. Accordingly, while the present disclosure has been described herein in detail in relation to its preferred embodiment, it is to be understood that this disclosure is only illustrative and exemplary of the present disclosure and is made merely for purposes of providing a full and enabling disclosure of the disclosure. The foregoing disclosure is not intended or to be construed to limit the present disclosure or otherwise to exclude any such other embodiments, adaptations, variations, modifications and equivalent arrangements.

Claims

THAT WHICH IS CLAIMED:1 . A glass manufacturing apparatus comprising: a melting vessel comprising a flow block assembly, the flow block assembly comprising: at least one refractory brick, wherein the at least one refractory brick comprises an exterior side facing away from an inside volume of the refractory and an interior side facing toward the inside volume of the refractory, wherein at least a portion of the interior side comprises a cladding of a cladding material, wherein the cladding material is corrosion resistant; and a tube disposed through the at least one refractory brick, wherein the tube defines an interior end and an opposite exterior end, wherein the interior end extends beyond the interior side of the at least one refractory brick, and the exterior end extends beyond the exterior side of the at least one refractory brick.

2. The glass manufacturing apparatus of claim 1, wherein the cladding material comprises a platinum alloy.

3. The glass manufacturing apparatus of any of claims 1-2, wherein the cladding material comprises platinum and rhodium.

4. The glass manufacturing apparatus of any of claims 1-3, wherein the cladding defines a cladding thickness, wherein the cladding thickness is between 1 - 1.5 mm.

5. The glass manufacturing apparatus of any of claims 1-4, wherein the tube comprises a first section adjacent the interior end and a second section adjacent the exterior end.

6. The glass manufacturing apparatus of claim 5, wherein the first section is crimped.

7. The glass manufacturing apparatus of any of claims 5-6, wherein the second section is smooth.

8. The glass manufacturing apparatus of any of claims 1-7, wherein the tube further comprises a tube flange extending from the tube proximate the exterior end.

9. The glass manufacturing apparatus of any of claims 1-8, wherein the tube is welded to the cladding.

10. The glass manufacturing apparatus of any of claims 1-9, further comprising: a flange defining a front face and an opposite rear face, wherein the rear face is disposed on the exterior side of the at least one refractory brick, and wherein the flange is radially spaced apart from the exterior end of the tube.

11. The glass manufacturing apparatus of any of claims 1-10 wherein the at least one refractory brick further comprises a first side and an opposite second side, wherein the cladding extends to each of the first side and the second side.

12. The glass manufacturing apparatus of any of claims 1-11, wherein the cladding defines a fillet at a juncture between a back face of the cladding and a first side of the cladding and between the back face of the cladding and a second side of the cladding.

13. The glass manufacturing apparatus of claim 12, wherein the fillet defines a radius of curvature greater than 3 mm.

14. A melting vessel comprising: a plurality of walls comprising at least one front wall comprising a flow block assembly, the flow block assembly comprising: at least one refractory brick comprising an exterior side facing away from an inside volume of the refractory and an interior side facing toward the inside volume of the refractory, at least a portion of the interior side comprising a cladding formed from a corrosion resistant cladding material; and a tube disposed through the at least one refractory brick, the tube comprising an interior end and an opposite exterior end, the interior end extending beyond theinterior side of the at least one refractory brick, and the exterior end extending beyond the exterior side of the at least one refractory brick.

15. The melting vessel of claim 14, wherein the cladding material comprises platinum.

16. The melting vessel of any of claims 14-15, wherein the cladding material comprises platinum and rhodium.

17. The melting vessel of any of claims 14-16, wherein the cladding defines a cladding thickness, wherein the cladding thickness is between 1 - 1.5 mm.

18. The melting vessel of any of claims 14-17, wherein the tube comprises a first section adjacent the interior end and a second section adjacent the exterior end.

19. The melting vessel of any of claims 18, wherein the first section is crimped.

20. The melting vessel of any of claims 18-19, wherein the second section is smooth.

21. The melting vessel of any of claims 14-20, wherein the tube is welded to the cladding.

22. The melting vessel of any of claims 14-21, further comprising: a flange defining a front face and an opposite rear face, wherein the rear face is disposed on the exterior side of the at least one refractory brick, and wherein the flange is radially spaced apart from the exterior end of the tube.

23. The melting vessel of any of claims 14-22 wherein the at least one refractory brick further comprises a first side and an opposite second side, wherein the cladding extends to each of the first side and the second side.

24. The melting vessel of any of claims 14-23, wherein the cladding defines a fillet at a juncture between a back face of the cladding and a first side of the cladding and between the back face of the cladding and a second side of the cladding.

25. A method of mitigating temperature drop within a melting vessel, the method comprising: providing a melting vessel, wherein the melting vessel is bound by a plurality of walls, and wherein the plurality of walls comprises at least one flow block assembly, wherein the flow block assembly comprises: at least one refractory brick, wherein the at least one refractory brick comprises an exterior side facing away from an inside volume of the refractory and an interior side facing toward the inside volume of the refractory, wherein at least a portion of the interior side comprises a cladding formed from a corrosion resistant cladding material; and a tube disposed through the at least one refractory brick, wherein the tube defines an interior end and an opposite exterior end, wherein the interior end extends beyond the interior side of the at least one refractory brick, and the exterior end extends beyond the exterior side of the at least one refractory brick; and providing molten glass to the melting vessel.

Images