Correlating the melting rates of feeds in electric melters with results of simple laboratory experiments can help evaluate melter feed additives and their effects on melting rate, and support the feed scheduling and plant operation. A recently proposed melting rate correlation (MRC) equation, relating the melting rate to melt viscosity, feed‐to‐glass conversion heat, and cold‐cap bottom temperature, was tested using data from experiments covering various feed compositions and melter operating parameters. The MRC equation is shown to reasonably represent the measured data and thus can be used to quantify how individual variables (melt viscosity, cold‐cap bottom temperature, conversion heat, melter operating temperature, and bubbling flux) affect the glass production rate.

No abstract

No abstract

During the final stages of batch‐to‐glass conversion in a waste‐glass melter, gases evolving in the cold cap produce primary foam, the formation and collapse of which control the glass production rate via its effect on heat transfer to the reacting batch. We performed quantitative evolved gas analysis (EGA) for several HLW melter feeds with temperatures ranging from 100 to 1150°C, the whole temperature span in a cold cap. EGA results were supplemented with visual observation of batch‐to‐glass transition using the feed expansion tests. Upon heating, most of the gases—mainly H2O, CO2, NO, NO2, N2, and O2—evolve at temperatures below 700°C and escape directly to the atmosphere through open porosity. However, as open porosity closes when enough glass‐forming melt appears at ~720°C, the residual gas evolution leads to the formation of primary foam. We found that primary foaming is mostly caused by the decomposition of residual carbonates, though oxygen evolution from iron‐redox reaction can also play a role. We also show that the gas evolution shifts to a higher temperature when the heating rate increases. The implications for the mathematical modeling of foam layer in the cold cap are presented.

Conversion of melter feed to glass occurs in the cold cap that floats on the melt pool in a nuclear waste glass melter. The conversion rate (the melting rate or the glass production rate) is controlled by the heat flux delivered to the cold cap from the molten glass. In an attempt to analyze the intricate relationship between the rate of heating, the feed foaming response, and the rate of melting, we measured the change in feed volume at different heating rates by using several melter feeds known to exhibit a wide range of melting rates under identical melter operating conditions. As expected, the maximum foam porosity increased as the heating rate increased.However, contrary to expectation, the temperature at which the foam reached maximum volume either decreased or increased with the heating rate, depending on the feed composition. A change in maximum foam temperature from the feed volume expansion test indicates a similar change of the cold-cap bottom temperature, which influences the heat flow to the cold cap, and thus the rate of melting. K E Y W O R D Sfeed-to-glass conversion, foaming, heat flux, melting rate 402 | LEE Et aL.

High‐level waste feed composition affects the overall melting rate by influencing the chemical, thermophysical, and morphological properties of a cold cap layer that floats on the molten glass where most feed‐to‐glass reactions occur. Data from X‐ray computed tomography imaging of melting pellets comprised of a simulated high‐aluminum feed reveal the morphology of bubbles, known as the primary foam, for various feed compositions at temperatures between 600°C and 1040°C. These feeds were formulated to make glasses with viscosities ranging from 0.5 to 9.5 Pa s at 1150°C, which was accomplished by changing the SiO2/(B2O3+Na2O+Li2O) ratio in the final glass. Pellet dimensions and profile area, average and maximum bubble areas, bubble diameter, and void fraction were evaluated. The feed viscosity strongly affects the onset of the primary foaming and the foam collapse temperature. Despite the decreasing amount of gas‐evolving components (Li2CO3, H3BO3, and Na2CO3), as the feed viscosity increases, the measured foam expansion rate does not decrease. This suggests that the primary foaming is not only affected by changes in the primary melt viscosity but also by the compositional reaction kinetic effects. The temperature‐dependent foam morphological data will be used to inform cold cap model development for a high‐level radioactive waste glass melter.

A recently proposed glass melting rate correlation (MRC) equation expresses an essential relationship between the melting rate and material and process variables (melt viscosity, cold‐cap bottom temperature, feed‐to‐glass conversion heat, melter operating temperature, and bubbling flux). It agreed well with data for high‐level waste (HLW) melter feeds processed in an electric melter. However, the nonlinear form and four coefficients made the original MRC somewhat cumbersome for representing existing data sets. Introducing new variables (glass melt density and depth of melt pool) makes the new MRC more broadly applicable. Also, reducing the number of coefficients to two simplifies it substantially. The simplified generalized MRC demonstrates good agreement with an extended data set encompassing additional melter feeds and melter sizes.

No abstract