Glass-Clay Melter Lining That Melts Away Without Glass Defects
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Solution Overview
Problem
Conventional ceramic refractory liners in glass melting apparatuses, particularly in submerged combustion melters, are prone to cracking and erosion due to turbulence caused by combustion products, leading to refractory pieces contaminating the molten glass and resulting in commercial defects in glass products.
Innovation Solution
A composite material comprising glass and inorganic non-metallic solids, such as clay and reinforcing fibers, is used to construct the inner layer of the glass melting apparatus walls, which are designed to integrate with the molten glass upon dislodgment, minimizing contamination and detectability of foreign pieces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional ceramic refractory liners are used in submerged combustion melters, then the furnace can withstand the thermal and mechanical stress, but the liner cracks and erodes over time due to turbulence from combustion products
Solution Approach 1:
The patent applies composite materials by combining glass particles (20-95 wt%) with inorganic non-metallic solids (clay, refractory materials, fibers) to create a refractory composite that integrates with molten glass. This composite structure provides both thermal resistance and compatibility with the glass melt, preventing the cracking and erosion that occurs with conventional ceramic liners.
2Reliability
If conventional ceramic refractory liners are used, then the furnace structure remains stable, but refractory pieces become separated and contaminate the molten glass causing commercial defects
Solution Approach 1:
The patent uses homogeneity by incorporating glass particles (20-95 wt%) into the refractory composite material. This ensures that if pieces do become dislodged, they are composed of glass that is chemically identical to the molten glass, making them indistinguishable and preventing commercial defects in the glass products.
3Object-generated harmful factors
If refractory liner maintenance or replacement is performed, then the contamination issue is resolved, but production efficiency decreases due to process interruption
Solution Approach 1:
The patent employs a disposable refractory composite lining that is designed to be replaced periodically without significant disruption to production. The composite material's unique glass content allows for relatively easy replacement compared to conventional ceramic liners, and the design enables maintenance operations to be scheduled during off-peak hours, minimizing impact on overall manufacturing efficiency.
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 composite material effectively reduces the occurrence of glass defects by ensuring that dislodged pieces melt into the glass, maintaining production efficiency and product quality.
Implementation Method 1
dislodged pieces melt into the glass
Implementation Method 2
The wall may be liquid cooled
Data Source
AI summary
A glass melting apparatus, such as a submerged combustion melter, has a housing that includes at least one wall, which may be liquid cooled. The wall includes an inner composite layer that faces an interior chamber of the melting apparatus and, in operation of the apparatus, contacts molten glass. The inner composite layer is comprised of a composite material that includes glass and clay and, additionally, may further include one or more of a refractory material, reinforcing fibers, an adhesion agent, or an atomizing agent. The wall of the housing may be provided by a plurality of panels with each panel providing a portion of the inner composite layer. A method of making the composite material from a castable material, which may be an aqueous slurry that includes water and a solids mixture, is also disclosed.