Layered Glass Pellets for Energy-Efficient Melting
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Solution Overview
Problem
Glass manufacturing processes face inefficiencies due to high energy consumption and heat loss when using loose glass batches, which lead to increased environmental impact and costs, and existing pelletized batches do not optimize the melting process by maintaining high viscosity throughout, requiring excessive energy to melt components.
Innovation Solution
A pellet design featuring a core of silica with eutectic or near-eutectic layers, where each layer is composed of specific mixtures such as SiO2 and Na2O, and Na2CO3 and CaCO3, allowing for sequential melting and reducing overall energy requirements by lowering viscosity before introducing silica, thereby optimizing the glass melt process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If loose glass batches are used in the melting process, then the glass ingredients can be easily mixed and fed into the furnace, but heat is lost from the top of the melter and energy consumption increases
Solution Approach 1:
The glass batch is segmented into multiple pellets with different compositions and melting points. Each pellet is designed to melt at a specific temperature stage, creating a controlled melting sequence that reduces heat loss and improves energy efficiency.
Solution Approach 2:
The batch materials are pre-processed into pellets with specific compositions before being fed into the furnace. This preliminary action ensures that the materials are optimally prepared for sequential melting, reducing the energy required during the actual melting process.
2Stability of the object's composition
If homogeneous glass batch pellets are used, then the composition is uniform throughout, but excessive energy is required to melt all components simultaneously
Solution Approach 1:
The homogeneous pellet is segmented into concentric layers with different compositions. The outer layers contain materials with lower melting points (such as sodium carbonate and calcium carbonate), while the inner core contains silica. This segmentation enables sequential melting, reducing the overall energy required.
Solution Approach 2:
Different regions of the pellet are assigned different compositions tailored to specific melting stages. The outer layers are designed to melt first and create a liquid medium, while the inner core melts later. This local quality differentiation optimizes the melting process efficiency.
3Stability of the object's composition
If traditional batch mixing is used, then all ingredients are combined in a homogeneous mixture, but the glass melting point remains high requiring excessive energy
Solution Approach 1:
The traditional homogeneous batch is segmented into layered pellets with strategically positioned materials. This segmentation allows the furnace to melt materials in sequence rather than simultaneously, significantly reducing the peak temperature and energy consumption required.
Solution Approach 2:
The batch materials are pre-arranged in a specific layered configuration before being fed into the furnace. This preliminary arrangement ensures that lower-melting-point materials are positioned to melt first, creating conditions that facilitate the subsequent melting of higher-melting-point materials like silica.
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 use of layered pellets reduces energy consumption by up to 15-20% per unit of glass produced, enhancing energy efficiency and minimizing environmental impact while improving the glass manufacturing process.
Implementation Method 1
at least one of the layers over the core being a eutectic layer or a near eutectic layer
Data Source
AI summary
The present invention relates to pellets for use in the manufacture of glass.