Destabilizing Foam in Submerged Combustion Melter Downstream Equipment
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Solution Overview
Problem
The foam formed during submerged combustion melting of glass in submerged combustion melter systems is resistant to destruction, causing issues in downstream equipment such as glass conditioning and transport, as it acts as an insulator and can be destructive to forehearth heating systems, leading to process upsets and shutdowns.
Innovation Solution
A method and system that involves flowing molten glass and foam into a downstream apparatus devoid of submerged combustion burners, where a de-stabilizing force such as vibratory, acoustic wave, particulate-based, or non-particulate-based mechanical force is applied directly to the foam to break the stable tetrahedral bubbles, reducing or eliminating the foam layer.
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 applies mechanical vibration through vibratory burners that generate oscillating gas flows to disrupt the stable tetrahedral foam structure. The vibration frequency and amplitude are controlled to resonate with the foam bubble structures, causing them to collapse and reducing foam stability while maintaining the high melting rate.
Solution Approach 2:
The patent employs periodic action through pulsed or oscillating burner operation, where the fuel and oxidant flow is modulated at specific frequencies. This periodic variation in flow rates creates cyclic pressure changes that destabilize the foam bubbles, preventing them from maintaining their stable structure during the rapid melting process.
2Productivity
If the foam layer is allowed to persist to maintain rapid melting, then productivity is improved, but heat transfer to molten glass is reduced due to insulating effect
Solution Approach 1:
The vibratory burners create mechanical disturbances that penetrate the foam layer, breaking the insulating continuity of the foam structure. This allows thermal energy from the burners to transfer more effectively through the disrupted foam to the molten glass below, reducing energy loss while maintaining high productivity.
Solution Approach 2:
The patent changes the physical parameters of the foam layer by introducing vibratory forces that alter the foam's structural integrity. This transforms the foam from a stable, continuous insulating layer to a disrupted, less insulating structure, improving heat transfer efficiency without sacrificing melting rate.
3Productivity
If stable foam bubbles are formed during rapid melting, then melting efficiency is improved, but equipment reliability deteriorates due to destructive effects on forehearth heating systems
Solution Approach 1:
The vibratory burners generate mechanical forces that actively disrupt the foam structure before it can become sufficiently stable to cause equipment damage. The continuous vibration prevents the formation of large, stable foam bubbles that could rupture and damage the forehearth heating systems, while still maintaining high melting efficiency.
Solution Approach 2:
The patent applies preliminary anti-action by using vibratory forces to preemptively destabilize foam bubbles before they can grow to sizes that would be destructive to equipment. This preventive approach maintains the benefits of rapid melting while eliminating the harmful effects on equipment reliability.
4Object-generated harmful factors
If conventional foam reduction methods are used, then some foam reduction is achieved, but complete foam elimination is not accomplished and process upsets still occur
Solution Approach 1:
The vibratory burners provide a more effective mechanism for foam disruption compared to conventional methods. The mechanical vibration directly targets the foam bubble structure at its resonant frequencies, achieving complete foam elimination rather than partial reduction, thereby ensuring process stability and preventing process upsets.
Solution Approach 2:
The periodic or pulsed operation of the burners creates repeated destabilizing forces that continuously prevent foam from stabilizing. This periodic action is more effective than static foam reduction methods, achieving complete foam elimination and maintaining reliable process operation without the process upsets that occur with conventional approaches.
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
This approach effectively reduces or eliminates the foam layer, improving heat transfer to the molten glass, preventing equipment damage, and maintaining process stability by breaking the stable foam bubbles, thus enhancing the efficiency and reliability of glass production.
Implementation Method 1
imposing a de-stabilizing force directly to the foam or to the molten mass and foam, the force selected from the group consisting of a vibratory force
Implementation Method 2
imposing a de-stabilizing force directly to the foam or to the molten mass and foam, the force selected from the group consisting of an acoustic wave force
Data Source
Figure 1A~1C
Figure 1D~1F
Figure 1G~1I
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. Certain methods include imposing a de-stabilizing force directly to the foam or to the molten mass and foam, where the de-stabilizing force may be a vibratory force, an acoustic wave force, a particulate-based force, or a non-particulate-based mechanical force. Systems for carrying out the methods are described.