Hydrogen-Oxygen Melting and Refining for Low-Emission Glass Ceramics
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Solution Overview
Problem
The production of glass ceramics requires high energy input, particularly for achieving the necessary high temperatures, and involves the use of environmentally harmful refining agents like Sb2O3 and As2O3, which need to be reduced for ecological and regulatory compliance, while maintaining glass properties.
Innovation Solution
A method using H2 and O2 combustion for melting and refining, with controlled oxygen-to-fuel ratios, reduces CO2 emissions and minimizes the use of multivalent oxides, achieving a glass ceramic with low thermal expansion and improved refining efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If conventional fossil fuel combustion is used for melting and refining, then high temperatures are achieved, but CO2 emissions are high
Solution Approach 1:
The patent changes the chemical composition parameters of the combustion process by replacing fossil fuel with hydrogen as the energy source. This fundamental parameter change transforms the combustion reaction from carbon-based to hydrogen-based, eliminating CO2 emissions while maintaining the high temperatures required for glass ceramic production
Solution Approach 2:
The patent substitutes the chemical system (fossil fuel combustion) with an alternative chemical system (hydrogen combustion). This substitution replaces the harmful carbon-based combustion mechanism with a clean hydrogen-based mechanism that produces water instead of CO2, while delivering equivalent thermal energy
2Productivity
If multivalent oxide refining agents (Sb2O3, As2O3) are used, then refining efficiency is improved, but environmental harm increases
Solution Approach 1:
The patent extracts and removes the harmful multivalent oxide refining agents (Sb2O3, As2O3) from the production process. By eliminating these toxic substances entirely and replacing them with hydrogen combustion, the process achieves refining without environmental harm while maintaining productivity
Solution Approach 2:
The patent converts the harmful byproducts of traditional refining into beneficial outcomes by using hydrogen combustion. The hydrogen oxidation process produces water instead of toxic emissions, transforming a potentially harmful chemical process into an environmentally beneficial one that eliminates pollution
3Productivity
If SnO2 is used as refining agent in high concentrations, then refining is improved, but glass transmission and crystallization susceptibility deteriorate
Solution Approach 1:
The patent changes the concentration parameter of SnO2 from high to low levels. By reducing the SnO2 concentration to minimal amounts, the process maintains sufficient refining capability while eliminating the negative effects on glass transmission and crystallization resistance that occur at high concentrations
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 method significantly reduces CO2 emissions, minimizes the use of harmful refining agents, and produces high-quality glass ceramics with low thermal expansion and reduced bubble formation, suitable for precision components.
Implementation Method 1
melting and/or refining is performed with heating by way of H2 and O2 combustion
Implementation Method 2
the refining gas diffuses into existing bubbles and enlarges these to such an extent that the bubbles rise in the melt and can leave it
Implementation Method 3
CO2 and H2O bubbles which are formed during the melting process, e.g. as a result of the decomposition of the raw materials based on carbonate or hydroxide
Implementation Method 4
ceramizing the glass which can be ceramized to form glass ceramic
Data Source
AI summary
A method for producing a glass ceramic includes: providing a batch of raw materials; heating the batch of raw materials until a melt is obtained, the batch of raw materials being heated at least in a plurality of sections to a temperature above T3 which corresponds to a viscosity of a molten glass of 103 dPa*s; refining the melt, the melt being heated at least in a plurality of sections to a temperature above T2.5 which corresponds to a viscosity of the molten glass of 102.5 dPa*s; obtaining a refined glass which is configured for being ceramized to form a glass ceramic material; and ceramizing a glass which is configured for being ceramized to form the glass ceramic material, at least one of the step of heating until the melt is obtained and the step of refining being performed with heating by way of H2 and O2 combustion.