Submerged Combustion Melter Cooling Wall Panels

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Solution Overview

Problem

Submerged combustion melting (SCM) processes experience splashing of molten vitreous material, causing strain on fluid-cooled wall panels and leading to unwanted passages that allow cooling fluid to bypass sections, resulting in boiling and restricted flow.

Innovation Solution

The implementation of continuous flow submerged combustion melter cooling wall panels with a serpentine coolant channel design, featuring a primary metal plate and welded 90-degree metal pieces, which form a staggered or parallel configuration to create efficient coolant flow channels, reducing the likelihood of splashing and strain on panel materials.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If traditional fluid-cooled wall panels are used in submerged combustion melters, then cooling function is provided, but splashing of molten material opens unwanted passages allowing cooling fluid to bypass sections, causing boiling and flow restriction

Engineering Contradiction:

Improvecooling system reliabilityVSAvoidsplashing damage to panels

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The cooling wall panel uses a composite structure combining a porous refractory layer with a metal backing plate containing coolant channels. The porous refractory material (such as vermiculite, perlite, or expanded graphite) acts as a splash barrier while allowing heat transfer, protecting the metal plate from direct molten material contact and preventing passage formation that would compromise cooling reliability

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The panel design applies different materials with specific properties to different regions: the porous refractory layer faces the molten material to absorb splashing, while the solid metal plate with embedded channels provides structural support and coolant flow paths. This localized material assignment optimizes each region's function - the refractory handles thermal shock and mechanical impact, while the metal plate ensures continuous cooling

Inventive Principle:

Principle #3Local quality

2Productivity

If aggressive mixing and turbulence are used to reduce melting time, then productivity increases, but splashing of molten material increases causing strain on panel materials

Engineering Contradiction:

Improvemelting speedVSAvoidpanel material strength

Core Design Contradiction:

ProductivityVSStrength

Solution Approach 1:

The invention converts the harmful effect of splashing into a beneficial one by using the porous refractory layer to absorb and dissipate the kinetic energy of molten material droplets. The splashing that would otherwise damage the panel is instead utilized to preheat the refractory material and enhance turbulence at the melt surface, while the refractory barrier protects the structural integrity of the cooling panel

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

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 design effectively reduces the occurrence of unwanted passages and boiling, ensuring consistent coolant flow and extending the lifespan of the cooling system by minimizing the impact of splashing and turbulence.

Implementation Method 1

a serpentine coolant channel design, featuring a primary metal plate and welded 90-degree metal pieces, which form a staggered or parallel configuration to create efficient coolant flow channels

Methodology Applied

Scientific EffectHeat conduction: Conduction (thermal)

Implementation Method 2

ensuring consistent coolant flow and extending the lifespan of the cooling system

Methodology Applied

Scientific EffectConvection: Convection

Implementation Method 3

Submerged combustion melting (SCM) involves melting glass-forming materials, mineral wool forming materials, rock wool forming materials, and other non-metallic inorganic feedstock materials by passing oxygen, oxygen-air mixtures or air along with a liquid, gaseous fuel, or particulate fuel directly into a molten or semi-molten pool of material

Methodology Applied

Scientific EffectCombustion: Combustion

Data Source

PatentUS11396470B2Continuous flow submerged combustion melter cooling wall panels, submerged combustion melters, and methods of using same

Publication Date: 2022.07.26 JOHNS MANVILLE CORP

AI summary

Continuous flow submerged combustion melter cooling wall panels, including a primary metal plate, and several 90 degree metal pieces welded to the primary metal plate in parallel configuration, each of the 90 degree metal pieces having metal leg plates forming a 90 degree vertex there between. Each metal leg plate has an edge distal to the vertex, the distal edge of the first metal leg plate welded to the first major surface of the primary metal plate, the distal edge of the second metal leg plate welded to the vertex of an adjacent 90 degree metal piece. The plurality of 90 degree metal pieces may have a length (l) such that l<L, each welded to the primary metal plate in staggered configuration to form, along with first and second end plates and a seal plate, a serpentine continuous flow coolant channel.