Zircon Furnace Components With Halide-Denuded Outer Layer
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Solution Overview
Problem
Zircon components used in glass melt furnaces face challenges with high silicon oxide content leading to undesirable bubbling and porosity issues, which affect their performance and longevity in glass processing.
Innovation Solution
A zircon component with a body comprising zircon grains and an intergranular silicon oxide phase, where the outer portion is treated to reduce silicon oxide content through exposure to a halide, such as fluorine, creating a denuded region with higher porosity and reduced silicon oxide content, while maintaining a higher silica content in the interior portion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If zircon components are used in glass melt furnaces, then high corrosion resistance and glass contact qualities are achieved, but transient blistering and porosity issues occur due to high silicon oxide content
Solution Approach 1:
The patent applies different silicon oxide content levels to different regions of the zircon component. The outer portion is treated to have reduced silicon oxide content (SOOPIP) to prevent blistering, while the interior portion maintains higher silicon oxide content (SOOPIP) to preserve corrosion resistance. This local differentiation resolves the contradiction by optimizing each region for its specific function.
Solution Approach 2:
The zircon component is segmented into an outer portion and an interior portion with distinct silicon oxide content characteristics. The outer portion is treated separately through halide exposure to remove intergranular silicon oxide, creating a denuded region that prevents blistering, while the interior maintains the original composition for structural integrity and corrosion resistance.
2Object-generated harmful factors
If silicon oxide content is reduced in the outer portion, then transient blistering is minimized, but porosity differences between interior and exterior portions increase
Solution Approach 1:
The patent accepts and manages the porosity difference as a local quality characteristic. The outer portion is designed with higher porosity (denuded region) to prevent blistering, while the interior maintains lower porosity for structural stability. This local differentiation is optimized to achieve the desired balance between blistering prevention and structural integrity.
3Reliability
If the outer portion is treated to remove silicon oxide, then glass contact qualities are improved, but the component structure becomes more complex
Solution Approach 1:
The halide treatment is applied as a preliminary action before the component is put into service. By pre-treating the outer portion to remove silicon oxide and create the denuded region, the component is prepared in advance to prevent blistering during actual glass melting operations, improving glass contact qualities without adding complexity during operation.
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 treatment significantly reduces transient blistering and porosity differences between the outer and inner portions, enhancing the component's durability and performance in glass manufacturing by minimizing silicon oxide interaction with the glass melt.
Implementation Method 1
exposing the body to a halide to at least partially remove the intergranular phase along an outer portion of the component. The halide can be fluorine (F), and can be provided by introducing at least one of HF, NH4HF2, or NH4F into an aqueous solution.
Data Source
AI summary
A zircon body for use in glass manufacturing is provided containing zircon grains and an intergranular phase present between the zircon grains. The intergranular phase may contain silicon oxide. The body may be exposed to a halide to at least partially remove at least a majority of the silicon oxide contained in the intergranular phase from the outer portion or to at least partially remove the intergranular phase along an outer portion of the component.