Halide-Treated Zircon Components to Reduce Glass Melt Blistering
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Solution Overview
Problem
Zircon components used in glass melt furnaces face challenges with high silicon oxide content leading to undesirable glass melt interaction, such as transient blistering, which affects the efficiency and quality of glass formation.
Innovation Solution
A zircon component with a body comprising zircon grains and an intergranular silicon oxide phase, where the outer portion is treated to reduce silicon oxide content, typically by exposing it to a halide like fluorine, resulting in a higher porosity region that minimizes silicon oxide interaction with the glass melt.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If zircon component is used in glass melt furnace, then high corrosion resistance and glass contact qualities are achieved, but silicon oxide content causes bubbling and porosity issues
Solution Approach 1:
The patent applies local quality by creating a gradient structure where the outer portion (contacting glass melt) has reduced silicon oxide content to prevent bubbling, while the interior portion maintains higher silicon oxide content for structural integrity. This is achieved through selective removal of intergranular phase from the outer region only.
Solution Approach 2:
The patent extracts the harmful silicon oxide-rich intergranular phase from the outer portion of the zircon component. By removing this phase from the surface region while retaining it in the interior, the component eliminates bubbling issues at the glass melt interface without compromising overall structural properties.
2Object-generated harmful factors
If silicon oxide content is reduced in outer portion, then bubbling is reduced, but porosity increases
Solution Approach 1:
The patent applies local quality by creating a gradient structure where the outer portion (contacting glass melt) has reduced silicon oxide content to prevent bubbling, while the interior portion maintains higher silicon oxide content for structural integrity. This is achieved through selective removal of intergranular phase from the outer region only.
Solution Approach 2:
The patent utilizes porous materials by intentionally creating a controlled porosity in the outer portion through removal of the intergranular phase. This controlled porosity prevents bubbling by eliminating pathways for gas accumulation, while the overall component density is maintained through the intact interior structure.
3Reliability
If intergranular phase is removed from outer portion, then resistance to glass melt interactions is improved, but manufacturing complexity increases
Solution Approach 1:
The patent applies preliminary action by performing the removal of the silicon oxide-rich intergranular phase from the outer portion before the component is put into service. This pre-treatment is done through chemical etching or thermal processing to create a protected surface layer that prevents bubbling during subsequent glass melt contact, eliminating the need for complex in-service repairs or adjustments.
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 treatment significantly reduces transient blistering and enhances the performance of zircon components in glass furnaces by creating a region with reduced silicon oxide content, improving the interaction with molten glass and reducing bubbling issues.
Implementation Method 1
exposing the body to a halide to at least partially remove the intergranular phase along an outer portion of the component
Data Source
AI summary
A zircon body for use in glass manufacturing is provided containing zircon grains and an intergranular phase present between the zircon grains. The intergranular phase may contain silicon oxide. The body may be exposed to a halide to at least partially remove at least a majority of the silicon oxide contained in the intergranular phase from the outer portion or to at least partially remove the intergranular phase along an outer portion of the component.