Modular Batch Delivery for Scalable Glass Melter Feed

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Solution Overview

Problem

Conventional batch houses in glass manufacturing plants are inflexible and costly to expand, making it impractical to increase the output capacity to accommodate additional submerged combustion melters or changing production demands, and they do not align with the operational flexibility of submerged combustion melting techniques.

Innovation Solution

A batch delivery system comprising a shared batch distribution unit and companion batch distribution units that can be scaled up or down to meet changing glass production needs, using automated guided vehicles and pneumatic conveyance to deliver partial and counterpart batch materials to form the final batch feed material for submerged combustion melters.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If a conventional batch house is constructed to support maximum glass capacity, then the initial production capacity is sufficient, but the system becomes inflexible and costly to expand when additional capacity is needed

Engineering Contradiction:

Improveinitial production capacityVSAvoidexpandability

Core Design Contradiction:

ProductivityVSAdaptability or versatility

Solution Approach 1:

The batch delivery system is divided into modular components: a shared batch distribution unit and multiple companion batch distribution units. Each companion unit can be independently added or removed based on production needs, allowing incremental capacity expansion without requiring complete system redesign or major construction projects.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The shared batch distribution unit serves multiple companion batch distribution units simultaneously, providing a universal platform that can support different numbers of melters. This multi-functional design allows the same core infrastructure to adapt to varying production capacities by simply adding or removing companion units as needed.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Productivity

If a batch house is expanded to increase output capacity, then production capacity increases, but capital investment and construction complexity increase significantly

Engineering Contradiction:

Improveoutput capacityVSAvoidcapital investment

Core Design Contradiction:

ProductivityVSEase of manufacture

Solution Approach 1:

The system separates batch distribution functions into discrete, addable modules. Companion batch distribution units can be manufactured and installed independently, allowing capacity expansion through incremental purchases rather than large capital projects. This reduces upfront investment risk and allows phased financing.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The system is designed to be dynamically scalable, where the number of active companion batch distribution units can be adjusted over time based on market conditions and production demands. This dynamic capability allows the plant to optimize capital expenditure by activating only the number of units currently needed.

Inventive Principle:

Principle #15Dynamics

3Reliability

If a conventional batch house is designed for continuous melting furnaces, then it works well for traditional processes, but it does not align with the operational flexibility of submerged combustion melters

Engineering Contradiction:

Improveprocess compatibilityVSAvoidoperational flexibility

Core Design Contradiction:

ReliabilityVSAdaptability or versatility

Solution Approach 1:

The batch delivery system is designed to universally support both continuous melting furnaces and submerged combustion melters through its modular architecture. The shared and companion distribution units can serve different melter types simultaneously, allowing the same infrastructure to adapt to various melting processes and operational schedules.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The system accommodates dynamic operational patterns by allowing companion batch distribution units to be independently controlled and timed. This enables synchronization with the specific operational cycles of submerged combustion melters, which may require batch delivery at different rates and schedules compared to continuous furnaces.

Inventive Principle:

Principle #15Dynamics

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

Enables flexible and efficient delivery of batch feed materials to submerged combustion melters, allowing incremental adjustments to output capacity without significant capital investment, and enabling different batch compositions for varying glass production requirements.

Implementation Method 1

the partial batch material is delivered from the shared batch distribution unit by pneumatically conveying the partial batch material from the pneumatic sender

Methodology Applied

Scientific EffectPneumatic conveyance:

Data Source

PatentUS20260008709A1Batch delivery system for glass manufacturing

Publication Date: 2026.01.08 OWENS BROCKWAY GLASS CONTAINER INC

AI summary

A batch delivery system is disclosed that includes a shared batch distribution unit and at least one companion batch distribution unit. The shared batch distribution unit supplies a partial batch material to the companion batch distribution unit. A counterpart batch material is added to the partial batch material at the companion batch distribution unit to form a batch feed material that is ultimately delivered to a glass production line for melting. A glass manufacturing plant that includes the batch delivery system and related methods are also disclosed.