Process and device for melting and fining glass
10414682 ยท 2019-09-17
Assignee
Inventors
Cpc classification
Y02P40/57
GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
International classification
C03B5/182
CHEMISTRY; METALLURGY
Abstract
The invention relates to a process and a device for manufacturing molten glass comprising from upstream to downstream a furnace for melting and fining glass equipped with cross-fired overhead burners, then a conditioning basin supplied with glass by the furnace, the dimensions of this manufacturing device being such that K is higher than 3.5, the factor K being determined from the dimensions of the device. The invention makes it possible to dimension a device for melting glass so that it is smaller and consumes less energy while producing high quality glass.
Claims
1. A process for manufacturing molten glass in a device comprising, from upstream to downstream, a furnace for melting and fining glass equipped with cross-fired overhead burners, and then a conditioning basin comprising one or more compartments, the process comprising melting glass in the furnace, wherein: the furnace comprises a melting zone and a fining zone; the bottom of the fining zone and the bottom of the conditioning basin are deep enough that a single downstream recirculation loop passes through the fining zone and through all the compartments of the conditioning basin; the conditioning basin is supplied with glass by the furnace; and the dimensions of the device are such that K is higher than 3.5, where:
2. The process of claim 1, wherein K>5.5.
3. The process of claim 2, wherein K>7.5.
4. The process of claim 3, wherein K is higher than 9.
5. The process of claim 1, wherein a ratio of the area under flame in the furnace to the area of the conditioning basin is higher than 1.4.
6. The process of claim 5, wherein the ratio of the area under flame in the furnace to the area of the conditioning basin is higher than 1.6.
7. The process of claim 6, wherein the ratio of the area under flame in the furnace to the area of the conditioning basin is higher than 1.8.
8. The process of claim 1, wherein the furnace is sufficiently deep that an upstream recirculation loop and the downstream recirculation loop form in the furnace.
9. The process of claim 1, wherein the conditioning basin comprises, from upstream to downstream, a neck then a working end.
10. The process of claim 1, wherein the furnace has a capacity of 500 to 1500 m.sup.3 of glass.
11. The process of claim 1, having a pull of 400 to 1300 tonnes of glass per day.
12. The process of claim 1, wherein the cross-fired overhead burners use an oxidant comprising 10 to 30 vol % O.sub.2, and are equipped with regenerators and function pairwise in reversal mode.
13. The process of claim 1, wherein the cross-fired overhead, burners use an oxidant containing 80 to 100 vol % O.sub.2.
14. The process of claim 1, wherein in the conditioning basin in any vertical plane transverse to the longitudinal axis of the furnace, there are points in the glass having a longitudinal velocity component pointing from downstream to upstream.
15. The process of to claim 1, wherein after the conditioning basin, the glass passes into a channel itself supplying a forming device, with no backflow occurring in the channel.
16. The process of claim 15, wherein a length of the channel ranges from 0.3 to 10 m.
17. A process for manufacturing flat glass, the process comprising manufacturing a molten glass with the process of claim 1, and then forming the molten glass into flat glass by floating the molten glass on a molten metal bath in a float chamber.
18. A device for manufacturing molten glass, the device comprising, from upstream to downstream, a furnace for melting and fining glass equipped with cross-tired overhead burners, and then a conditioning basin comprising one or more compartments, wherein: the furnace comprises a melting zone and a fining zone; the bottom of the fining zone and the bottom of the conditioning basin are deep enough that a single downstream recirculation loop passes through the fining zone and through all the compartments of the conditioning basin; the conditioning basin is supplied with glass by the furnace; and the dimensions of the device are such that K is higher than 3.5, where:
19. The device of claim 18, wherein K>5.5.
20. The device of claim 19, wherein K>7.5.
21. The device of claim 20, wherein K is higher than 9.
22. The device of claim 18, wherein a ratio of the area under flame in the furnace to the area of the conditioning basin is higher than 1.4.
23. The device of claim 22, wherein the ratio of the area under flame in the furnace to the area of the conditioning basin is higher than 1.6.
24. The device of claim 23, wherein the ratio of the area under flame in the furnace to the area of the conditioning basin is higher than 1.8.
25. The device of claim 18, wherein a ratio of the area under flame in the furnace to the area of the conditioning basin is lower than 4.
26. The device of claim 18, wherein the furnace is deep enough that an upstream recirculation loop and the downstream recirculation loop form in the furnace.
27. The device of claim 18, wherein the conditioning basin comprises, from upstream to downstream, a neck then a working end.
28. The device of claim 18, wherein the furnace has a capacity of 500 to 1500 m.sup.3 of glass.
29. The device of claim 18, having a pull of 400 to 1300 tonnes of glass per day.
30. The device of claim 18, wherein the cross-fired burners use an oxidant comprising 10 to 30 vol % O.sub.2, and are equipped with regenerators and function pairwise in reversal mode.
31. The device of claim 18, wherein in the conditioning basin in any vertical plane transverse to the longitudinal axis of the furnace, there are points in the glass having a longitudinal velocity component pointing from downstream to upstream.
32. The device of claim 18, wherein after the conditioning basin, a glass being manufactured passes into a channel itself supplying a forming device, with no backflow occurring in the channel.
33. The device of claim 32, wherein a the length of the channel ranges from 0.3 to 10 m.
34. A device for manufacturing flat glass, the device comprising the device of claim 18, and a float chamber in which a molten glass is floated on a molten metal bath.
35. The device of claim 18, further comprising, over its entire length, tank blocks containing the molten glass, wherein glass height is a distance between the upper level of the tank blocks decreased by a safety margin of between 30 and 130 mm and the level of the bottom.
36. The process of claim 3, wherein K is higher than 10.5.
37. THE process of claim 1, wherein: K>5.5; a ratio of the area under flame in the furnace to the area of the conditioning basin is higher than 1.4; the furnace is sufficiently deep that an upstream recirculation loop and the downstream recirculation loop form in the furnace; in the conditioning basin in any vertical plane transverse to the longitudinal axis of the furnace, there are points in the glass having a longitudinal velocity component pointing from downstream to upstream; and after the conditioning basin, the glass passes into a channel itself supplying a forming device, with no backflow occurring in the channel.
38. The device of claim 20, wherein K is higher than 10.5.
39. The device of claim 18, wherein: K>5.5; a ratio of the area under flame in the furnace to the area of the conditioning basin is higher than 1.4; the furnace is deep enough that an upstream recirculation loop and the downstream recirculation loop form in the furnace; in the conditioning basin in any vertical plane transverse to the longitudinal axis of the furnace, there are points in the glass having a longitudinal velocity component pointing from downstream to upstream; and after the conditioning basin, a glass being manufactured passes into a channel itself supplying a forming device, with no backflow occurring in the channel.
Description
(1) The figures described below are not to scale.
(2)
(3)
(4)
(5)
(6)
EXAMPLES 1 TO 19
(7) All the examples were carried out in a device such as shown in
(8) For all the examples:
(9) the length of the melting zone was 26 675 mm;
(10) the width of the melting and fining zones was 13 000 mm;
(11) the length of the fining zone was 17 000 mm;
(12) the distance between the end of the area under flame and the inlet of the neck was 14 075 mm;
(13) h.sub.f represents the glass height in the melting zone;
(14) h.sub.a represents the glass height in the fining zone;
(15) V.sub.fa represents the volume of glass in the furnace;
(16) L.sub.c represents the length of the neck;
(17) I.sub.c represents the width of the neck;
(18) h.sub.c represents the glass height in the neck;
(19) L.sub.b represents working end length;
(20) I.sub.b represents working end width;
(21) h.sub.b represents the glass height in the working end;
(22) Q represents the quality of the glass relative to the quality of the glass of Example 1 (reference case) i.e. the difference between the quality of the glass of the Example i in question and the quality of the glass of Example 1, the sum being divided by the quality of Example 1 Q=(Q.sub.iQ.sub.1)/Q.sub.1; it is the average time spent at above 1400 C. that is considered. This Q is multiplied by 100 in Table 1 in order to express the result in percent;
(23) Conso represents the energy consumption of the entire device relative to the consumption of Example 1, i.e. the difference between the consumption of the Example i in question and the consumption of Example 1, the sum being divided by the consumption of Example 1: Conso=(Conso.sub.iConso.sub.1)/Conso.sub.1; this Conso is multiplied by 100 in Table 1 in order to express the result in percent; and
(24) Souff represents the intensity of blown cooling of the working end relative to the intensity of blown cooling of the working end of Example 1, i.e. the difference between the intensity of blown cooling of the working end of the Example i in question and the intensity of blown cooling of the working end of Example 1, the sum being divided by the intensity of blown cooling of the working end of Example 1: Souff=(Souff.sub.iSouff.sub.1)/Souff.sub.1; this Souff is multiplied by 100 in Table 2 in order to express the result in percent.
(25) TABLE-US-00001 TABLE 1 h.sub.f h.sub.a V.sub.fa L.sub.c l.sub.c h.sub.c L.sub.b l.sub.b h.sub.b Q Conso Ex No. (m) (m) (m.sup.3) (m) (m) (m) (m) (m) (m) K (%) (%) 1 1.45 1.45 823 7 4.8 1.45 17 12 1.45 2.31 0 0.0 2 1.45 1.45 823 7 4.8 1.45 12.75 9 1.45 2.35 7 1.8 3 1.45 1.27 783 7 4.8 1.27 12.75 9 1.27 3.63 3 1.2 4 1.45 1.27 783 7 4.8 1.27 12.75 9 0.89 5.07 11 3.5 5 1.45 1.27 783 7 4.8 0.89 12.75 9 0.89 5.67 12 4.1 6 1.45 1.27 783 7 6.5 0.89 12.75 9 0.89 8.50 23 6.9 7 1.45 1.27 783 7 4.8 1.27 12.75 9 0.6 9.86 28 8.2 8 1.45 1.27 783 7 4.8 0.89 12.75 9 0.89 10.01 26 7.4 9 1.45 1.27 783 4.5 4.8 0.89 12.75 9 0.89 11.46 31 8.6 10 1.45 1.27 783 7 4.8 0.89 12.75 13 0.89 11.65 31 8.3 11 2 2 1136 7 4.8 0.89 12.75 9 0.89 12.02 28 7.2 12 1.45 1.45 823 7 4.8 0.89 12.75 9 0.89 12.26 27 8.5 13 1.45 1.27 783 7 4.8 0.89 12.75 9 0.89 12.45 28 8.4 14 2 1.27 974 7 4.8 0.89 12.75 9 0.89 12.45 28 7.5 15 1.27 1.27 721 7 4.8 0.89 12.75 9 0.89 12.45 27 9.3 16 1.45 0.89 700 7 4.8 0.89 12.75 9 0.89 13.51 32 8.9 17 1.45 1.27 783 7 4.8 0.89 12.75 4.8 0.89 15.17 36 9.1 18 1.45 1.27 783 7 3.7 0.89 12.75 9 0.89 18.22 36 9.7 19 1.45 1.27 783 7 4.8 0.89 12.75 9 0.89 21.76 41 9.9
(26) The values of K.sub.a and of K.sub.S due to the lowerable barrier (where K=K.sub.a+K.sub.S), the conditioning basin area characteristics and the blowing characteristics are detailed in Table 2, .sub.sc representing the minimal cross section of flow of the glass produced by the barrier in the neck (by way of singular element), S.sub.c representing the area of glass making contact with the atmosphere in the neck, S.sub.b being the area of glass making contact with the atmosphere in the working end, S.sub.cond representing the area of the glass making contact with the atmosphere in the conditioning basin (where S.sub.cond=S.sub.c+S.sub.b), and S.sub.f/S.sub.cond representing the ratio of the area under flame to the area of glass making contact with the atmosphere in the conditioning basin.
(27) TABLE-US-00002 TABLE 2 Ex No. Ka .sub.sc (m.sup.2) K.sub.s K S.sub.c (m.sup.2) S.sub.b (m.sup.2) S.sub.cond (m.sup.2) S.sub.f/S.sub.cond Souff (%) 1 1.75 5.04 0.56 2.31 33.6 204 237.6 1.37 0 2 1.79 5.04 0.56 2.35 33.6 114.75 148.35 2.20 119 3 2.55 4.176 1.07 3.63 33.6 114.75 148.35 2.20 83 4 4.00 4.176 1.07 5.07 33.6 114.75 148.35 2.20 55 5 5.67 4.272 0 5.67 33.6 114.75 148.35 2.20 46 6 4.84 3.185 3.65 8.50 45.5 114.75 160.25 2.04 14 7 8.78 4.176 1.07 9.86 33.6 114.75 148.35 2.20 7 8 5.73 2.592 4.29 10.01 33.6 114.75 148.35 2.20 11 9 4.77 2.352 6.70 11.46 21.6 114.75 136.35 2.39 17 10 4.96 2.352 6.70 11.65 33.6 165.75 199.35 1.64 38 11 5.32 2.352 6.70 12.02 33.6 114.75 148.35 2.20 0 12 5.56 2.352 6.70 12.26 33.6 114.75 148.35 2.20 6 13 5.75 2.352 6.70 12.45 33.6 114.75 148.35 2.20 2 14 5.75 2.352 6.70 12.45 33.6 114.75 148.35 2.20 2 15 5.75 2.352 6.70 12.45 33.6 114.75 148.35 2.20 3 16 6.81 2.352 6.70 13.51 33.6 114.75 148.35 2.20 2 17 8.47 2.352 6.70 15.17 33.6 61.2 94.8 3.44 89 18 6.94 1.813 11.27 18.22 25.9 114.75 140.65 2.32 6 19 5.84 1.872 15.92 21.76 33.6 114.75 148.35 2.20 15
(28) The examples are numbered from 1 to 19 in order of increasing factor K. It will be noted that there is a correlation between the quality Q obtained for the glass and the factor K, a higher quality glass being obtained in examples 3 to 19. As may be seen it is recommendable for K to be higher than 3.5 and preferably higher than 5.5 and even more preferably higher than 7.5. The energy consumptions of Examples 3 to 19 are also good. Small working ends of 114.75 m.sup.2 are generally enough, except in Example 2 where the blowing intensity is too high. For the blowing intensity used in Example 1, the risk of optical defects appearing on the surface of the glass is low. In contrast, this risk is real in the case of Example 2, since a conditioning basin area of 148.35 m.sup.2 requires a Souff higher than 119% of that of Example 1. It will be noted that if Souff is higher than 90% of that of Example 1, then the risk of optical defects appearing on the surface is too high, which is the case for Example 2. Preferably, Souff is lower than 85% of that of Example 1. In order to achieve this, K should be sufficiently high, in accordance with the present invention, and the ratio of the area under flame to the area of the conditioning basin (S.sub.f/S.sub.cond) should be lower than 4 and preferably lower than 3, and even more preferably lower than 2.5. In the case of Example 10, the area of the conditioning basin is very large and therefore costly to produce, this high area explaining the low blowing intensity. In this configuration, the area of the conditioning basin could be decreased.
(29) In all the examples, the bottom temperature was below 1360 C.
(30) In all the examples except example 7, the glass contained residual bubbles in an amount of less than 50%. Example 7 corresponds to Example 4 except that the depth of the working end was 600 mm. Because of the small depth of the working end, the recirculation loop passing through the conditioning basin also passed through the neck and a good part of the working end but did not reach as far as the inlet of the channel. In the last 7 meters of the working end, the flow of the glass was a plug flow. At the inlet of the channel the glass contained residual bubbles in an amount of 60%.
EXAMPLE 20
(31) The device had the same dimensions as the device of Example 1, except that there was no barrier, and the depth of the working end was decreased by 50% (to 0.72 m) and the width of the working end was decreased to 6 meters. The value of K was 10.22. The recirculation loop passing through the conditioning basin passed through the neck and a portion of the working end but did not extend as far as the channel since there was no recirculation in the last 7 meters of the working end, the flow then being a plug flow. At the channel inlet, the glass contained 50.4% residual bubbles. The other results were as follows: Souff=24%, Sf/Scond=2.41 and Q=8.