The present invention relates to a process for melting solid batch material, comprising the steps of introducing solid batch material into a melter, and melting the solid batch material in the melter by submerged combustion and subjecting the melt to a flow pattern which when simulated on a computer by making use of common fluid dynamic equations shows a substantially toroidal melt flow pattern in the melt, comprising a major centrally inwardly convergent flow at the melt surface, the central axis of revolution of the toroid being substantially vertical. The invention further relates to a melter assembly for carrying out the process. The toroidal melt flow pattern is achieved by suitable arrangement, angle and spacing of multiple submerged combustion burners in the floor of the melter.

The present invention relates to a process for melting solid batch material, comprising the steps of introducing solid batch material into a melter, and melting the solid batch material in the melter by submerged combustion and subjecting the melt to a flow pattern which when simulated on a computer by making use of common fluid dynamic equations shows a substantially toroidal melt flow pattern in the melt, comprising a major centrally inwardly convergent flow at the melt surface, the central axis of revolution of the toroid being substantially vertical. The invention further relates to a melter assembly for carrying out the process. The toroidal melt flow pattern is achieved by suitable arrangement, angle and spacing of multiple submerged combustion burners in the floor of the melter.

A molten material furnace system having a liquid cooled flow control mechanism and method are disclosed. In particular, the flow control mechanism can include a needle including: a longitudinal axis; an outer conduit including an outer base end, an outer body, and an outer free end; an inner conduit including an inner base end, an inner body radially spaced from the outer body, an inner free end, and a central inlet passage extending between the inlet and the inner free end. Also disclosed is a needle control assembly to position the flow control needle relative to a stilling tank outlet orifice to control flow of molten material through the outlet orifice.

A molten material furnace system having a liquid cooled flow control mechanism and method are disclosed. In particular, the flow control mechanism can include a needle including: a longitudinal axis; an outer conduit including an outer base end, an outer body, and an outer free end; an inner conduit including an inner base end, an inner body radially spaced from the outer body, an inner free end, and a central inlet passage extending between the inlet and the inner free end. Also disclosed is a needle control assembly to position the flow control needle relative to a stilling tank outlet orifice to control flow of molten material through the outlet orifice.

A submerged combustion melter 10 is arranged with a vertical melting chamber 11, which may be cylindrical, and at least five submerged combustion burners 21-26 in the bottom base 13, the burners so spaced apart from each other and from the walls and angled from the vertical that in use a toroidal flow pattern can be achieved, providing intensive mixing. The claims also pertain to a method of melting a vitrifiable material from solid batch by submerged combustion melting.

A submerged combustion melter 10 is arranged with a vertical melting chamber 11, which may be cylindrical, and at least five submerged combustion burners 21-26 in the bottom base 13, the burners so spaced apart from each other and from the walls and angled from the vertical that in use a toroidal flow pattern can be achieved, providing intensive mixing. The claims also pertain to a method of melting a vitrifiable material from solid batch by submerged combustion melting.

Submerged combustion glass manufacturing systems include a melter having a floor, a roof, a wall structure connecting the floor and roof, and an exhaust passage through the roof. One or more submerged combustion burners are mounted in the floor and/or wall structure discharging combustion products under a level of material being melted in the melter and create turbulent conditions in the material. The melter exhausts through an exhaust structure connecting the exhaust passage with an exhaust stack. The exhaust structure includes a barrier defining an exhaust chamber having an interior surface, the exhaust chamber having a cross-sectional area greater than that of the exhaust stack but less than the melter. The barrier maintains temperature and pressure in the exhaust structure at values sufficient to substantially prevent condensation of exhaust material on the interior surface.

Submerged combustion glass manufacturing systems include a melter having a floor, a roof, a wall structure connecting the floor and roof, and an exhaust passage through the roof. One or more submerged combustion burners are mounted in the floor and/or wall structure discharging combustion products under a level of material being melted in the melter and create turbulent conditions in the material. The melter exhausts through an exhaust structure connecting the exhaust passage with an exhaust stack. The exhaust structure includes a barrier defining an exhaust chamber having an interior surface, the exhaust chamber having a cross-sectional area greater than that of the exhaust stack but less than the melter. The barrier maintains temperature and pressure in the exhaust structure at values sufficient to substantially prevent condensation of exhaust material on the interior surface.

A molten material furnace system having a liquid cooled flow control mechanism and method are disclosed. In particular, the flow control mechanism can include a needle including: a longitudinal axis; an outer conduit including an outer base end, an outer body, and an outer free end; an inner conduit including an inner base end, an inner body radially spaced from the outer body, an inner free end, and a central inlet passage extending between the inlet and the inner free end. Also disclosed is a needle control assembly to position the flow control needle relative to a stilling tank outlet orifice to control flow of molten material through the outlet orifice.

A molten material furnace system having a liquid cooled flow control mechanism and method are disclosed. In particular, the flow control mechanism can include a needle including: a longitudinal axis; an outer conduit including an outer base end, an outer body, and an outer free end; an inner conduit including an inner base end, an inner body radially spaced from the outer body, an inner free end, and a central inlet passage extending between the inlet and the inner free end. Also disclosed is a needle control assembly to position the flow control needle relative to a stilling tank outlet orifice to control flow of molten material through the outlet orifice.