Hydrogen-Fueled Glass Article Melting with Water Vapor and Foam Control
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Solution Overview
Problem
The use of hydrocarbon fuels in glass manufacturing increases carbon dioxide emissions and leads to an increase in water vapor partial pressure, causing foam layer expansion which reduces energy efficiency.
Innovation Solution
A manufacturing method using hydrogen fuel with controlled water vapor partial pressure and carbonate-containing glass raw materials to reduce carbon dioxide emissions and suppress foam layer expansion, combined with multistage combustion and gas supply to stabilize molten glass production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-generated harmful factors
If hydrogen fuel is used to replace hydrocarbon fuel, then carbon dioxide emissions are reduced, but water vapor partial pressure increases causing foam layer expansion and reduced energy efficiency
Solution Approach 1:
The patent controls the water vapor partial pressure in the melting furnace by adjusting the hydrogen fuel supply rate and air supply rate, maintaining the water vapor partial pressure at 80% or less of total atmospheric pressure. This parameter control prevents excessive foam layer expansion while still using hydrogen fuel, thereby resolving the contradiction between reducing carbon dioxide emissions and maintaining energy efficiency
Solution Approach 2:
The patent dynamically adjusts the fuel supply rate and air supply rate based on the melting state and foam layer thickness. By making the combustion process adjustable and responsive to real-time conditions, the system can optimize energy efficiency while maintaining the environmental benefits of hydrogen fuel usage
2Object-generated harmful factors
If hydrogen fuel is burned to reduce carbon dioxide, then water is generated increasing water vapor partial pressure, but this causes foam layer expansion and reduces heat transfer to molten glass
Solution Approach 1:
The patent maintains water vapor partial pressure at 80% or less of total atmospheric pressure by controlling the hydrogen combustion process. This parameter control prevents the foam layer from becoming too thick, ensuring that heat can still be effectively transferred from the flame through the foam layer to the molten glass while maintaining reduced carbon dioxide emissions
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
Efficient and stable molten glass production is achieved with reduced carbon dioxide emissions and improved energy efficiency by controlling water vapor partial pressure and foam layer thickness.
Implementation Method 1
When the hydrogen fuel is burned to form a flame, water is generated as a main product
Implementation Method 2
a water vapor partial pressure in the melting furnace is increased because of water generated along with the combustion
Implementation Method 3
an increase in water vapor partial pressure in the melting furnace causes expansion of air bubbles formed by the action of the fining agent
Implementation Method 4
The foam layer has a low heat transfer property. Thus, when the thickness of the foam layer is increased, heat of the flame formed by the burner is less likely to be conducted to the molten glass
Data Source
AI summary
In a melting step (S1) of generating a molten glass (Gm) by heating and melting glass raw materials (Gr) corresponding to raw materials for a glass article in a melting furnace (10), the glass raw materials (Gr) are heated and molten through combustion of fuel (FH) containing hydrogen, and a water vapor partial pressure (Pp) in the melting furnace (10) is set to 80% or less of a total atmospheric pressure (Pt).