Submerged-burner furnace self-crucible wall grip texture
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Solution Overview
Problem
The self-crucible formed in furnaces with submerged burners and metal walls cooled by a fluid (water-jacket) cracks, fragments, and falls, exposing the metal wall to erosion and causing unpredictable heat transfers that destabilize the fusion process of vitrifiable materials like glass, due to the smooth surface and rapid solidification of the vitrifiable material, leading to inefficient energy use and corrosion.
Innovation Solution
A grip texture is applied to the metal wall with projecting elements forming an adhesion pattern of at least 5 mm depth, perpendicular to the surface, to stabilize the self-crucible, minimize heat transfers, and divert unburned gases back into the molten material, while reducing corrosion by using a refractory concrete with high alumina content to enhance chemical adhesion and protect the metal wall.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a smooth metal wall is used in the furnace, then the wall structure is simple and easy to manufacture, but the self-crucible layer becomes unstable and detaches
Solution Approach 1:
The invention applies a bonding texture only to the inner surface of the metal wall that contacts the self-crucible layer, while the outer surface remains smooth for structural integrity. This localized texturing provides anchoring points for the self-crucible without complicating the overall wall structure or manufacturing process.
2Productivity
If the vitrifiable material solidifies rapidly upon contact with the cooled wall, then the melting process is efficient, but the self-crucible structure becomes poorly formed and porous
Solution Approach 1:
The bonding texture is pre-formed on the metal wall surface before the vitrifiable material is introduced. This preliminary structuring of the wall surface ensures that when rapid solidification occurs, the self-crucible material has predetermined anchoring points to adhere to, preventing pore formation and structural defects while maintaining efficient heat transfer.
3Temperature
If combustion gases pass between the self-crucible and metal wall, then heat transfer to the vitrifiable material is improved, but corrosion of the metal wall increases
Solution Approach 1:
The bonding texture acts as an intermediary layer between the self-crucible and the metal wall. It allows controlled passage of combustion gases for heat transfer while simultaneously providing a protective interface that prevents direct contact between corrosive gases and the metal wall, thereby reducing corrosion.
4Device complexity
If the self-crucible detaches and falls, then the wall structure remains simple, but heat transfer becomes unpredictable and the fusion process destabilizes
Solution Approach 1:
The bonding texture creates localized anchoring zones distributed across the wall surface. These textured regions provide stable adhesion points for the self-crucible layer, ensuring it remains firmly attached during the fusion process. This prevents detachment and maintains predictable heat transfer, stabilizing the overall fusion process while keeping the wall structure relatively simple.
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
The solution stabilizes the self-crucible layer, improves energy efficiency by minimizing heat transfers, reduces corrosion of the metal wall, and extends its lifespan, ensuring a more consistent and efficient fusion process.
Implementation Method 1
a water-jacket cooling system is used for a submerged burner furnace in order to contain the temperature to which its structure is exposed
Implementation Method 2
the other face (3) of the metal sheet (1) being cooled, in particular by being in contact with the cooling fluid
Implementation Method 3
a bonding texture for devitrified vitrifiable material, called 'self-crucible', which will cover the interior wall of the furnace from the start of its operation
Implementation Method 4
the self-crucible had a poorly formed structure at its interface with the metal wall due to the rapid solidification of the vitrifiable material
Data Source
Figure 1~2b
Figure 3~4
Figure 5~7
AI summary
The invention relates to a furnace for melting vitrifiable material, in particular glass, said furnace having a submerged burner and a wall that is cooled by a cooling fluid, the wall surface facing the interior of the furnace comprising, prior to the vitrifiable material being melted in the furnace, an attachment texture for the devitrified vitrifiable material referred to as a self-crucible.