Submerged Combustion Melter Toroidal Flow Pattern

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Solution Overview

Problem

Conventional glass melters face inefficiencies in energy consumption and end product homogeneity due to suboptimal heat transfer and mixing of raw materials, particularly in submerged combustion processes, which affect the quality and consistency of vitrifiable materials like glass and stone wool production.

Innovation Solution

A submerged combustion melter with strategically arranged burners creating a toroidal melt flow pattern, optimized burner spacing, and liquid-cooled chamber design enhances heat absorption and mixing, reducing energy consumption and maintaining homogeneity in the melt, allowing for efficient melting of a wide range of materials including waste and raw materials.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Loss of energy

If conventional burners are used with flame above melt surface, then heat transfer is simpler, but energy consumption increases and melt homogeneity deteriorates

Engineering Contradiction:

Improveenergy consumptionVSAvoidburner arrangement complexity

Core Design Contradiction:

Loss of energyVSDevice complexity

Solution Approach 1:

The patent inverts the conventional burner arrangement by placing burners below the melt surface instead of above it. This submerged combustion approach allows the flame to burn directly within the melt, fundamentally changing the heat transfer mechanism from external radiation/convection to internal combustion, thereby reducing energy loss and improving melt homogeneity

Inventive Principle:

Principle #13The other way round (Inversion)

Solution Approach 2:

The patent introduces combustion products and hot gases as intermediaries that pass through the melt to transfer heat. The burners inject fuel and air to create combustion products that act as a heat-carrying medium, penetrating deep into the melt and distributing thermal energy uniformly throughout the material

Inventive Principle:

Principle #24Intermediary (Mediator)

2Productivity

If burners are arranged below melt surface, then energy efficiency improves, but heat transfer uniformity and mixing become problematic

Engineering Contradiction:

Improvemelting efficiencyVSAvoidmelt homogeneity

Core Design Contradiction:

ProductivityVSStability of the object's composition

Solution Approach 1:

The patent applies local quality by positioning multiple burners at different locations below the melt surface to create localized heating zones. Each burner provides intense heat at its specific location, and the combined effect of multiple distributed burners achieves uniform overall heating while maintaining high melting efficiency

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The patent employs a toroidal (doughnut-shaped) melt flow pattern that creates curved circulation paths. This toroidal flow geometry ensures that melt is continuously circulated through heated zones and cooler zones, distributing heat uniformly throughout the entire melt volume while maintaining stable composition

Inventive Principle:

Principle #14Spheroidality (Curvature)

3Ease of manufacture

If raw material is added at top of melt, then loading is simple, but heat transfer to batch material is inefficient

Engineering Contradiction:

Improveraw material loadingVSAvoidheat transfer efficiency

Core Design Contradiction:

Ease of manufactureVSUse of energy by moving object

Solution Approach 1:

The patent applies preliminary action by preheating the raw batch material as it falls through the hot atmosphere above the melt surface before it actually contacts the melt. The hot combustion gases and radiant heat from the submerged burners preheat the incoming material, reducing the thermal energy required to melt it and improving overall heat transfer efficiency

Inventive Principle:

Principle #10Preliminary action

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 submerged combustion melter achieves efficient melting with reduced energy consumption and improved melt homogeneity, enabling high-quality production of glass and stone wool with lower capital costs and maintenance, suitable for various applications including fiber production and waste vitrification.

Implementation Method 1

one or more submerged combustion burners arranged below a surface of the melt within the melting chamber

Methodology Applied

Scientific EffectCombustion: Combustion

Implementation Method 2

creating a toroidal melt flow pattern

Methodology Applied

Scientific EffectConvection: Convection

Implementation Method 3

liquid-cooled chamber design enhances heat absorption

Methodology Applied

Scientific EffectHeat conduction: Conduction (thermal)

Implementation Method 4

creating a toroidal melt flow pattern

Methodology Applied

Scientific EffectTurbulence: Turbulence

Implementation Method 5

enhances heat absorption and mixing

Methodology Applied

Scientific EffectConvection: Convection

Data Source

PatentUS11680004B2Submerged combustion melters and methods

Publication Date: 2023.06.20 KNAUF INSULATION SPRL

AI summary

A submerged combustion melter is arranged with a melting chamber, which may be cylindrical, and at least five submerged combustion burners.