Modeling batch melting: Roles of heat transfer and reaction kinetics

Abstract

Development of mathematical models of heat and mass transfer in glass‐melting furnaces began in the 1970s and progressed rapidly with advances in sophisticated experimental/numerical techniques and increasing computational power. Today, practically all newly built or rebuilt furnaces are optimized with these models to meet stringent quality requirements, reduce the unit costs of manufacturing, or control emissions. One remaining hurdle is to model the batch‐to‐glass conversion accurately enough to reliably assess the glass production rate. This article summarizes two key aspects of the batch‐conversion modeling—the heat transfer and the kinetics of conversion—and reviews the current state‐of‐the‐art approaches to simulating them. We critically examine the advantages of the commonly used heat transfer approach, but also explain that its predictive capabilities are significantly restricted by the dependence of batch thermal properties on the time‐temperature history. We argue that kinetic approaches to the batch‐conversion modeling would offer a significant improvement when coupled with the heat transfer approach. Finally, we summarize key areas requiring further research on the way toward a realistic model of the batch blanket.

Experimental and numerical investigations of an oxygen single‐bubble shrinkage in a borosilicate glass‐forming liquid doped with cerium oxide

“…As discussed earlier, in‐situ observation via camera imaging 26,27 is a beneficial technique for obtaining these data. It is a well‐established technique, employed to obtain information about glasses and melts at high temperatures 36‐39 . The apparatus consists of an electrical furnace coupled with a porthole, which geometrically links the glass melt sample to the charge‐coupled device (CCD) in the camera (Figure 3).…”

“…It is a well-established technique, employed to obtain information about glasses and melts at high temperatures. [36][37][38][39] The apparatus consists of an electrical furnace coupled with a porthole, which geometrically links the glass melt sample to the charge-coupled device (CCD) in the camera (Figure 3). Prior to the procedure, glass pieces (~50 g) are placed in a transparent silica crucible (height, H = 65 mm; thickness, K = 15 mm; and width, L = 35 mm), and the assembled apparatus is placed in the observation furnace and heated at 1150°C.…”

Model for batch-to-glass conversion: coupling the heat transfer with conversion kinetics

“…Over the past decades, mathematical modeling has become a tool for design and operation optimization of glass-melting furnaces aiming at reducing glass manufacturing costs, controlling glass quality, and complying with the ever-more-stringent environmental constraints. Yet simplifications necessitated by the complexity of the glass melting process continue to limit the ability of current models to predict the glass production rate, and consequently the furnace productivity [1][2][3][4]. Model performance would improve if crucial aspects of the batch conversion kinetics were adequately addressed.…”

Visual Observation of Foaming at the Batch-Melt Interface During Melting of Soda-Lime-Silica Glass

“…The results obtained in this work provide a clear information about the foam behavior during melting of container glass batch. Moreover, because the behavior of foam is directly linked to the heat and mass transfer between the batch and melt, the results of this work can help in future development of more realistic batch melting models [21,22].…”