Rotary Batch Preheater for Dust-Free Wet Glass Batch Heating
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Solution Overview
Problem
Existing batch preheaters in the glass industry face issues such as dust entrainment, agglomerate formation, large equipment size, high costs, and limited applicability due to the formation of agglomerates and dust, especially when handling wet glass batch materials.
Innovation Solution
A rotary, indirect tubular heat exchanger that heats wet glass batch by using furnace exhaust gases, converting soda ash to sodium carbonate monohydrate within the drum to prevent agglomeration, while maintaining a high relative humidity to facilitate dry and dust-free batch handling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If conventional batch preheaters are used to heat glass batch materials, then heat recovery from exhaust gases is achieved, but agglomerate formation and dust entrainment occur
Solution Approach 1:
The invention changes the physical and chemical parameters of the batch material by converting soda ash to sodium carbonate monohydrate through controlled hydration in the presence of moisture. This chemical transformation fundamentally alters the material properties to prevent agglomeration and dust formation during the preheating process, while maintaining effective heat recovery from exhaust gases.
Solution Approach 2:
The invention introduces moisture as an intermediary substance that facilitates the conversion of soda ash to sodium carbonate monohydrate. This intermediary agent enables the chemical transformation that prevents harmful effects without interfering with the heat transfer process from exhaust gases to the batch material.
2Use of energy by moving object
If batch preheating is implemented to reduce fuel consumption, then energy efficiency improves, but equipment size and cost increase
Solution Approach 1:
The rotary drum preheater performs multiple functions simultaneously: it heats the batch material using exhaust gas heat transfer, converts soda ash to sodium carbonate monohydrate through controlled hydration, and prevents agglomeration and dust formation. This multi-functionality is achieved within a single integrated device, avoiding the need for separate processing equipment and thereby reducing overall system complexity and cost.
3Adaptability or versatility
If wet glass batch materials are handled in conventional preheaters, then processing flexibility is improved, but handling difficulties and dust generation increase
Solution Approach 1:
The invention enables the wet batch material to self-regulate its moisture content during processing. The controlled conversion of soda ash to sodium carbonate monohydrate occurs naturally in the presence of the moisture already present in the wet material, eliminating the need for external drying equipment or complex moisture control systems. This self-service approach maintains processing flexibility while dramatically improving handling ease and reducing dust generation.
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 solution effectively prevents agglomeration, reduces dust generation, and enhances melting characteristics by converting soda ash to sodium carbonate monohydrate, leading to improved handling and reduced melting time and energy consumption.
Implementation Method 1
a rotary heat exchanger for indirectly transferring heat from glass furnace exhaust gases to wet glass batch material
Implementation Method 2
indirectly transferring heat from glass furnace exhaust gases to wet glass batch material
Implementation Method 3
exhaust gases flowing through the heat exchanger tubes to heat the batch material
Implementation Method 4
evaporate the water in the batch
Implementation Method 5
converting soda ash to sodium carbonate monohydrate within the drum
Data Source
AI summary
Rotary heat-exchanger for glass batch and/or cullet, comprising a stationary casing having a gas inlet and outlet, and an interior region between the gas inlet and outlet; a chamber positioned in the casing rotatable with respect to the casing and configured to receive batch material or a mixture with cullet; at least one heat exchange tube in the casing in fluid communication with the gas inlet and outlet; a feeder in communication with the chamber and comprising a feeder housing configured to discharge the batch material or mixture of batch material and cullet into the chamber along an infeed length and in contact with the at least one tube; wherein the infeed length is a length effective to heat the batch or mixture with cullet material up to at least 100° C. in the infeed length. A method of preheating glass batch is also disclosed.