Multi-chamber Submerged Combustion Melter Baffle Flow Control
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Solution Overview
Problem
Submerged combustion melters used in glass manufacturing often result in a glass batch exiting the melter in a relatively short time, risking unmelted or partially unmelted batches and limiting throughput improvement.
Innovation Solution
The implementation of at least one baffle or skimmer in the submerged combustion melter to create a series of melting sub-chambers, which directs and controls the flow of raw batch materials and molten glass, increasing residence time and preventing short-circuiting of un-melted materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Duration of action of moving object
If a single large melting chamber is used, then the device complexity is reduced, but the residence time of raw materials is insufficient causing unmelted batches to exit
Solution Approach 1:
The melting chamber is divided into multiple melting sub-chambers (first, second, and third sub-chambers) separated by baffles. This segmentation increases the residence time of raw materials by forcing them to traverse through multiple sub-chambers in sequence, while the overall device complexity is managed through a shared exhaust system and coordinated burner arrangement.
2Reliability
If multiple separate exhaust systems are used for each sub-chamber, then the control of gas flow is improved, but the device complexity and cost increase
Solution Approach 1:
Multiple melting sub-chambers share a common exhaust system with a single exhaust port. This merging approach reduces device complexity and eliminates the need for multiple separate exhaust systems, while reliable gas flow control is achieved through properly positioned baffles that guide combustion gases and molten glass flow through all sub-chambers before exiting.
3Productivity
If the glass batch moves quickly through the melter, then the productivity is improved, but the melting is incomplete resulting in unmelted materials
Solution Approach 1:
Raw glass batch is preheated in the first melting sub-chamber before entering subsequent sub-chambers. This preliminary action ensures that materials are progressively melted through staged heating, allowing complete melting to occur even as throughput is maintained, because each sub-chamber performs a specific heating function in sequence.
4Ease of operation
If baffles are added to create sub-chambers, then the flow control is improved, but the device complexity increases
Solution Approach 1:
Baffles are strategically positioned to divide the melting chamber into sequential sub-chambers, providing excellent flow control by directing glass batch through a predetermined undulating path. The complexity is minimized by using a limited number of baffles (first, second, and third baffles) that create effective segmentation without excessive structural complexity.
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 baffles in the submerged combustion melter enhances the control of batch flow, increases the residence time of raw materials, and ensures that molten glass is uniformly melted, reducing the risk of unmelted materials exiting the melter.
Implementation Method 1
mixing combustible fuels and oxidants with raw glass material and firing the fuels and oxidants under the surface of and directly into the glass material to be melted
Implementation Method 2
The contact between the raw glass material and the combusting fuels and oxidants generates a bubbling bath of molten glass with high rates of mass and heat transfer
Data Source
AI summary
A submerged combustion melter includes first, second, third, and fourth side walls extending upwardly from a bottom wall, a crown extending inwardly with respect to the side walls and over the bottom wall to establish a melting chamber, an exhaust port configured to exhaust gas from the melting chamber, a baffle coupled to and extending inwardly from the third side wall to divide the melting chamber into melting sub-chambers that share the exhaust port and having an end spaced away from the fourth side wall, an inlet configured for introducing a glass batch into the melter, and an outlet configured to remove molten glass from the melting sub-chambers, which direct product flow in a laterally undulating flow path from the inlet to the outlet.