Downstream Foam Destabilization in Submerged Combustion Melting
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Solution Overview
Problem
The foam produced during submerged combustion melting of glass-forming materials in submerged combustion melter systems is resistant to destruction, causing issues in equipment downstream, such as hindered glass conditioning and transport, and potential system shutdowns due to insulation and destructive properties.
Innovation Solution
A method and system involving a downstream apparatus devoid of submerged combustion burners, where a molten mass of glass and foam flows, and a composition of low momentum combustion products, fluids, or slurries is directly impinged onto the foam using low momentum burners, nozzles, or apertures to de-stabilize and reduce the foam.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If high flow rates of oxidant and fuel are introduced into the molten glass to achieve rapid melting, then melting speed is improved, but foam formation increases and becomes resistant to destruction
Solution Approach 1:
The patent extracts the foam destruction function from the melting process itself by introducing a separate downstream apparatus with impingement burners and nozzles. This dedicated foam treatment system removes the harmful foam phase from the molten glass flow path, allowing rapid melting to continue uninterrupted while foam is destroyed downstream through direct impingement of high-velocity gas streams.
Solution Approach 2:
The patent introduces an intermediary substance (gas stream from impingement burners or nozzles) to destroy the foam. This mediating gas phase acts as a tool to break down the foam structure without directly contaminating the molten glass, enabling rapid melting to proceed while foam is eliminated through the intermediary action of the impinging gas flow.
2Loss of energy
If foam layer is allowed to accumulate on top of molten glass to maintain temperature, then heat retention is improved, but glass conditioning and transport are hindered
Solution Approach 1:
The patent applies the skipping principle by allowing the foam layer to temporarily exist for heat retention, then rapidly destroying it through downstream impingement. The foam is not permanently eliminated but rather rushed through the system - maintained during melting for thermal benefit, then quickly destroyed downstream to enable proper glass conditioning and transport operations.
Solution Approach 2:
The patent implements periodic action through the cyclic formation and destruction of foam. Foam forms periodically during rapid melting to retain heat, then is periodically destroyed by the downstream impingement system. This rhythmic formation-destruction cycle allows the system to alternate between heat retention mode and glass conditioning mode, optimizing both functions over time.
3Stability of the object's composition
If stable tetrahedral foam bubbles are formed in the molten glass, then foam stability is improved for heat retention, but foam destruction becomes difficult requiring external influence
Solution Approach 1:
The patent applies preliminary anti-action by preparing the foam for destruction before it becomes problematic. The downstream apparatus is positioned to receive the foam-laden molten glass and immediately apply impingement forces. The anti-action (foam destruction) is preliminarily arranged in the process flow, so when foam forms and stabilizes for heat retention, it is already positioned to be destroyed by the waiting impingement system downstream.
Solution Approach 2:
The patent implements preliminary action by pre-positioning the foam destruction mechanism downstream before the foam causes operational problems. The impingement burners and nozzles are installed in advance in the downstream apparatus, ready to destroy foam as soon as it enters that section. This preliminary arrangement of destruction capability allows the foam to first serve its heat retention function, then be eliminated when the preliminary destruction system activates.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Effectively reduces or eliminates foam, improving heat transfer and preventing equipment damage, thereby enhancing the efficiency and reliability of glass manufacturing processes.
Implementation Method 1
combusting a fuel and an oxidant in one or more low momentum combustion burners positioned in the roof, the wall, or both to produce low momentum combustion products
Implementation Method 2
directly impinging an impinging composition comprising a majority of gas onto at least a portion of the foam in the downstream apparatus
Data Source
AI summary
Methods and systems for de-stabilizing foam produced in submerged combustion melters. A molten mass of glass and bubbles is flowed into an apparatus downstream of a submerged combustion melter. The downstream apparatus includes a floor, a roof and a wall connecting the floor and roof, but is devoid of submerged combustion burners and other components that would increase turbulence of the molten mass. The molten mass has foam on at least a portion of a top surface of the molten mass. One method includes directly impinging an impinging composition onto at least a portion of the foam in the downstream apparatus. Systems for carrying out the methods are described.