Foamed Glass Bubble Control via Downstream Atmosphere
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Submerged combustion melters produce glass with high void fractions and turbulent foams, which are challenging to control, leading to inefficiencies in glass fiber production and foam glass product quality.
Innovation Solution
A method involving a downstream apparatus with controlled atmospheric composition, temperature management, and the use of non-submerged oxy-fuel combustion burners to regulate bubble size and foam decay rate, either by bubbling oxygenated sulfur compounds or introducing alkali metal chalcogen particles and water vapor to stabilize or destabilize the foam as needed.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If submerged combustion melting is used to rapidly melt glass batch, then melting speed and productivity are improved, but void fraction and foam formation increase significantly
Solution Approach 1:
The patent applies preliminary action by introducing oxygen-enriched atmosphere and controlled oxidants into the melt pool before and during the combustion process. This pre-conditioning of the atmosphere allows for more complete combustion and better gas bubble coalescence, reducing void fraction while maintaining high melting speed. The burners are positioned to create specific flow patterns that promote bubble rise and coalescence before the glass solidifies.
Solution Approach 2:
The patent changes physical and chemical parameters including oxygen concentration in the atmosphere, temperature distribution in the melt pool, and combustion gas flow rates. By adjusting these parameters, the system optimizes the balance between rapid melting and void reduction. Specifically, oxygen-enriched atmospheres and controlled oxidation conditions alter the combustion characteristics and bubble behavior to reduce entrained air.
2Productivity
If high flow rates of combustion products are introduced into molten glass, then melting efficiency is improved, but turbulence and foam stability increase
Solution Approach 1:
The patent employs dynamic control of burner positions, fuel-to-air ratios, and oxygen enrichment levels to adapt to changing melt conditions. The system dynamically adjusts combustion product flow rates and introduces oxidants at different stages to control foam stability. This dynamic approach allows the system to maintain high melting efficiency while preventing excessive foam formation or stabilizing foam when desired for product quality.
Solution Approach 2:
The patent implements feedback control by monitoring foam height, melt temperature, and combustion characteristics, then adjusting burner operations and oxygen injection rates accordingly. Sensors detect foam level and void fraction, and the system responds by modifying combustion parameters to achieve the desired foam stability. This closed-loop control ensures consistent product quality while maintaining high productivity.
3Quantity of substance
If traditional foam reduction methods are applied to SCM glass, then some void reduction is achieved, but complete foam elimination is not accomplished
Solution Approach 1:
The patent uses oxygen-enriched atmospheres and direct oxygen injection as strong oxidants to accelerate combustion and improve gas bubble coalescence. The elevated oxygen concentration promotes more complete burning of combustion products and enhances the rise and merging of air bubbles, achieving superior void fraction reduction compared to traditional methods. This approach eliminates the need for complex multi-stage processing while achieving complete foam reduction.
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 controls bubble size and foam decay rate, enhancing the quality of glass products by reducing voids and optimizing heat penetration, suitable for both glass fiber and foam glass production.
Implementation Method 1
heating or maintaining temperature of the foamed glass using only combustion heating comprising one or more non-submerged oxy-fuel combustion burners
Implementation Method 2
bubbling a composition comprising an oxygenated sulfur compound and optionally oxygen below a level of the foamed glass... thereby stabilizing size of the glass foam bubbles and a foam decay rate
Implementation Method 3
dripping water through the gaseous atmosphere and onto at least a portion of the glass foam
Data Source
AI summary
Methods and systems for controlling bubble size and bubble decay rate of glass foams formed during submerged combustion melting. Flowing a molten mass of foamed glass comprising molten glass and bubbles entrained therein into an apparatus downstream of a submerged combustion melter. The downstream apparatus has a floor, a roof, and a sidewall structure connecting the floor and roof. The foamed glass has glass foam of glass foam bubbles on its top surface, and the downstream apparatus defines a space for a gaseous atmosphere above and in contact with the glass foam. The downstream apparatus includes heating components to heat or maintain temperature of the foamed glass. Adjusting composition of the atmosphere above the glass foam, and/or contacting the foam with a liquid or solid composition controls bubble size of the glass foam bubbles, and/or foam decay rate.