Forehearth Comprising Exchangeable Support Blocks

Abstract

The present invention concerns a glass fibre manufacturing plant comprising a forehearth forming a passage for conveying molten glass and defined by a first and second opposite longitudinal walls, wherein each longitudinal wall is made of a refractory masonry comprising a cavity of width, Wc, and height, H1c, formed by a floor defined by a base wall, by lateral walls defined by two spacer bricks and by a ceiling defined by a lintel resting on each of the two spacer bricks, and further comprising a support block (20) comprising a hot cuboid portion of width, w, and height, h, wherein w<Wc, and h<H1c, said hot cuboid portion being reversibly inserted in the cavity, thus defining a gap surrounding the hot cuboid portion of the support block when positioned in the cavity, said gap being filled with a resilient material (29), said forehearth being characterized in that, the masonry comprises a spacing element hindering the thermal expansion of the two spacer bricks, such that the distance, Wc, between said two spacer bricks measured at room temperature cannot be reduced below a predetermined hot cavity width, W, at said service temperature, hT, wherein said predetermined distance, W, is larger than the width, w, of the hot cuboid portion of the support block.

Claims

1. Glass fibre manufacturing plant comprising a forehearth (31) forming a passage for conveying molten glass (30) and defined by: a first and second opposite longitudinal walls (31L) having a hot longitudinal wall surface facing said passage and extending along a longitudinal direction, X1, having a longitudinal wall thickness extending along a first transverse direction, X2, normal to X1, and having a longitudinal wall height extending along a second transverse direction, X3, normal to both X1 and X2, a ceiling (31T), a bottom floor (31B) and an end wall (31E), wherein each longitudinal wall is made of a refractory masonry comprising: (a) a series of refractory base bricks (32) forming a base wall comprising a top surface for supporting, (b) two spacer bricks (23) lying on the top surface of the base wall and separated from one another at the level of the hot longitudinal wall surface by a distance, Wc, measured at room temperature (RT) along the longitudinal direction, X1, each spacer brick having a cuboid geometry comprising a hot surface (23H) forming a portion of the hot longitudinal wall surface, wherein, (c) a lintel (25) of length, WL>Wc, measured along the longitudinal direction, X1, at room temperature and comprising two opposite ends, each resting on one surface of one of the two spacer bricks, thus defining with the top surface of the base wall and the two spacer bricks, (d) a cavity (28) of width, Wc, and height, H1c, measured at the level of the hot longitudinal wall surface at room temperature along the longitudinal direction, X1, and along the second transverse axis, X3, respectively, and of depth, Dc, measured at room temperature along the first transverse axis, X2, (e) a support block (20) comprising a hot cuboid portion having a cuboid geometry of width, w, and height, h, measured along X1 and X3, respectively, at the level of the hot longitudinal wall surface at a service temperature, hT, of the forehearth of at least 1000 C., and of depth measured along X2 at least equal to D, wherein w<Wc, and h<H1c, said hot cuboid portion being reversibly inserted in the cavity, and (f) a gap surrounding the hot cuboid portion of the support block when positioned in the cavity, said gap being filled with a resilient material (29), characterized in that, the masonry comprises a spacing element hindering the thermal expansion of the two spacer bricks, such that the distance, Wc, between said two spacer bricks measured at room temperature along the longitudinal direction, X1, at the level of the hot longitudinal wall surface cannot be reduced below a predetermined hot cavity width, W, at said service temperature, hT, wherein said predetermined distance, W, is larger than the width, w, of the hot cuboid portion of the support block.

2. Glass fibre manufacturing plant according to claim 1, wherein, (a) The top surface of the base wall forms a planar surface along a base plane (X1, X2), (b) The two spacer bricks (23) are characterized in that, two opposite edges remote from the base plane and extending in the first transverse direction, X2, are cut off to form a right step at each of said two opposite edges, defining a recessed surface (23R) parallel to the base plane, and a stepping surface (23S) extending parallel to X3, at the service temperature (hT) the hot surface has a height, H2, measured along the second transverse direction, X3, and a height, H1, measured up to the recessed surfaces, the stepping surfaces (23S) of the steps thus having a height, HS=H2H1, (c) the two opposite ends of the lintel (25) each rests on one recessed surface (23R) of one of the two spacer bricks, wherein the spacing element is formed by the lintel (25) resting on the recessed surfaces (23R) and resisting the thermal expansion of the stepping surfaces (23S) of the two spacer bricks.

3. Glass fibre manufacturing plant according to claim 1 or 2, wherein a base spacer (26) of length equal to the predetermined distance, W, measured at said service temperature, hT, along the first longitudinal direction, lies on the top surface of the base wall between the two spacer bricks, such that the distance, H1, measured at the service temperature along the second transverse direction, X3, between said base spacer and the lintel is larger than the height, h, of the hot cuboid portion of the support portion, said base spacer thus forming the spacing element.

4. Glass fibre manufacturing plant according to claim 1, wherein the top surface of the base wall forms a merlon (27) of length equal to the predetermined distance, W, measured at said service temperature, hT, along the first longitudinal direction, said merlon separating the two spacer bricks, said merlon thus forming the spacing element.

5. Glass fibre manufacturing plant according to claim 1, wherein (a) The two spacer bricks (23) are characterized in that, two opposite edges adjacent to the top surface of the base wall and extending in the first transverse direction, X2, are cut off to form a right step at each of said two opposite edges, defining a recessed surface (23R) parallel to X1, and a stepping surface (23S) extending parallel to X3, measured along the second transverse direction, X3, at the service temperature (hT), the hot surface has a total height, H2, and a height, H1, measured down to the recessed surfaces, the step thus having a height, HS=H2H1, (b) the top surface of the base wall forms a merlon (27) of height, HS, measured along the second transverse direction, X3, and of length such that when the merlon contacts the stepping surfaces of the two spacer bricks, the distance between said two spacer bricks measured along the longitudinal direction, X1, at the level of the hot longitudinal wall surface at said service temperature, hT, is equal to the predetermined distance, W. wherein the spacing element is formed by the merlon (27) supporting the recessed surfaces (23R) of the two spacer bricks and resisting the thermal expansion of the stepping surfaces (23S) of the two spacer bricks.

6. Glass fibre manufacturing plant according to any one of claims 1 to 5, wherein the support block is selected among one of the following: (a) A burner block for supporting a burner, preferably an oxy-burner; (b) A measurement block for supporting a pressure or temperature measuring device; (c) A peep hole block for supporting a viewing device for observing the passage; (d) A camera block for supporting a camera for taking pictures or videos of the passage, (e) An injection block for supporting a gun for injecting a fluid at a predetermined location of the passage; or (f) An atmospheric beam, for controlling the gas flows within the passage.

7. Glass fibre manufacturing plant according to anyone of the preceding claims, wherein the gap at the level of the hot longitudinal wall surface has an average width, wg1=(Ww), measured at service temperature, hT, along the longitudinal direction, X1, comprised between 1 and 5 mm, and is preferably equal to 31 mm, and wherein the gap preferably has an average height, hg= (H1h), measured at service temperature, hT, along the second transverse axis, X2, comprised between 1 and 5 mm, and is preferably equal to 31 mm.

8. Glass fibre manufacturing plant according to anyone of the preceding claims, wherein the cavity (28) has tapered walls, with a width, Wt, and/or with a height, H1t, measured at room temperature at the level of a cold surface (23C) of the spacer bricks, opposite the hot surface (23H), along the longitudinal direction, X1, and along the second transverse axis, X3, respectively, which is larger than the width, Wc, and height, H1c, measured at the level of the hot longitudinal wall surface, Wt>Wc and/or H1t>H1c.

9. Glass fibre manufacturing plant according to claim 6, wherein the support block is a burner block comprising a cold surface (20C) and a hot surface (20H) opposite the cold surface, the cold surface being connected to the hot surface by a through-passage extending along a passage axis, Xp, said through-passage comprising three portions: (a) A burner portion (21B), opening at the cold surface, and having a cross-section suitable for accommodating a burner (1) having a body and a downstream end portion (1D) characterized by a large base adjacent to the body, and ending at a small base having a cross-section smaller than the cross-section of the large base; (b) A flame portion (21F), opening at the hot surface and converging along the passage axis, xp, in the direction of the cold surface until meeting (c) A joining portion (21J), fluidly joining the flame portion with the burner portion in which it opens with a cross-section of dimensions comprised between the one of the large base and the one of the small base, and wherein in a top view along a plane (X1, X2), the passage axis, Xp, forms an angle, , with the longitudinal direction, X1, comprised between 30 and 90, preferably, between 45 and 90, more preferably, =90, such that the passage axis, Xp, is parallel to the first transverse direction, X2.

10. Glass fibre manufacturing plant according to claim 9, wherein the burner block further comprises a cold cuboid portion comprising the cold surface and adjacent to the hot cuboid portion, wherein the cross-sectional area normal to the first transverse axis, X2, of the hot cuboid portion is smaller than the one of the cold cuboid portion.

11. Glass fibre manufacturing plant according to claim 9 or 10, wherein an oxy-burner (1) comprising a body extending along the passage axis, Xp, and enclosing a fuel line (1F) and an oxygen line (10x) separate from the fuel line, both fuel line and oxygen line having a separate outlet at or adjacent to a downstream end (1D) of the body of the oxy-burner, said downstream end of the oxy-burner body having a trunco-conical geometry is mounted in the burner portion of the burner block, with the downstream end being located partly in, or adjacent to the joining portion (21F) and being oriented towards the passage.

12. Glass fibre manufacturing plant according to any one of the preceding claims, wherein each longitudinal wall comprises at least two cavities (28), each cavity containing a support block (20) reversibly engaged therein, said at least two cavities being aligned horizontally and separated from one another by at least one spacer brick (23), the at least two cavities of the first longitudinal wall facing the at least two cavities of the second longitudinal wall preferably in a staggered arrangement, the end wall being preferably also provided with a cavity containing a support block (20) reversibly engaged therein.

13. Method for reversibly loading a support block (20) in a forehearth of a glass fibre manufacturing plant according to any one of the preceding claims, said method comprising: (A) building a forehearth as defined in claim 1, forming a passage for conveying molten glass (30) and defined by: a first and second opposite longitudinal walls (31L) having a hot longitudinal wall surface facing said passage and extending along a longitudinal direction, X1, having a longitudinal wall thickness extending along a first transverse direction, X2, normal to X1, and having a longitudinal wall height extending along a second transverse direction, X3, normal to both X1 and X2, a ceiling (31T), a bottom floor (31B) and an end wall (31E), wherein building each longitudinal wall comprises: (a) laying a series of refractory base bricks (32) to form a base wall comprising a top surface, (b) laying two spacer bricks (23) onto the top surface of the base wall, separated from one another at the level of the hot longitudinal wall surface by a distance, Wc, measured at room temperature (RT) along the longitudinal direction, X1, each spacer brick having a cuboid geometry comprising a hot surface (23H) forming a portion of the hot longitudinal wall surface, (c) providing a lintel (25) of length, WL>Wc, measured along the longitudinal direction, X1, and comprising two opposite ends, and laying each of the two opposite ends onto one of the two spacer bricks, thus defining with the base wall and the two spacer bricks a cavity (28) of width, Wc, and height, H1c, measured at the level of the hot longitudinal wall surface at room temperature along the longitudinal direction, X1, and along the second transverse axis, X3, respectively, and of depth, Dc, measured at room temperature along the first transverse axis, X2, (d) providing and installing a spacing element that hinders the thermal expansion of the two spacer bricks, such that the distance, Wc, between said two spacer bricks measured at room temperature along the longitudinal direction, X1, at the level of the hot longitudinal wall surface cannot be reduced below a predetermined distance, W, at a service temperature, hT, of the forehearth of at least 1000 C., (B) providing a support block (20) comprising a hot cuboid portion having a cuboid geometry of width, w, and height, h, measured along X1 and X3, respectively, at the level of the hot longitudinal wall surface at a service temperature, hT, of the forehearth of at least 1000 C., and of depth measured along X2 at least equal to D, wherein w<W<Wc, and h<H1c<H1, said hot cuboid portion comprising four peripheral surfaces meeting two by two at ridges extending transverse to the first longitudinal direction, X1, (C) coating the four peripheral surfaces of said hot cuboid portion with a layer of resilient material (29), and (D) reversibly inserting into the cavity the hot cuboid portion of the support block, which peripheral surfaces are coated with the resilient material.

14. Method according to claim 13, further comprising the steps of: (E) removing the support block from the cavity by sliding the hot cuboid portion along the first transverse axis, X2, (F) removing any resilient material left in the cavity, (G) reversibly inserting into the cavity the hot cuboid portion of a new support block as defined in (B), which peripheral surfaces are coated with the resilient material.

Description

BRIEF DESCRIPTION OF THE FIGURES

[0065] For a fuller understanding of the nature of the present invention, reference is made to the following detailed description taken in conjunction with the accompanying drawings in which:

[0066] FIG. 1: shows a front view of a longitudinal wall provided with support blocks according to an embodiment of the present invention.

[0067] FIG. 2: shows a front view of a longitudinal wall provided with support blocks according to an alternative embodiment of the present invention.

[0068] FIG. 3: shows a front view of a longitudinal wall provided with support blocks according to an alternative embodiment of the present invention.

[0069] FIG. 4: shows a front view of a longitudinal wall provided with support blocks according to an alternative embodiment of the present invention.

[0070] FIG. 5: shows a front view of a longitudinal wall provided with support blocks according to an alternative embodiment of the present invention.

[0071] FIG. 6: shows a front view of a longitudinal wall provided with support blocks according to an alternative embodiment of the present invention.

[0072] FIG. 7: shows (a) a cross-section, and (b) a top view of a portion of forehearth according to the present invention.

[0073] FIG. 8: shows a perspective view of a support block being inserted into a cavity provided in the masonry of a forehearth longitudinal wall according to an embodiment of the present invention.

[0074] FIG. 9: shows (a) a perspective, partly exploded view of a support block being inserted into a cavity provided in the masonry of a forehearth longitudinal wall according to an alternative embodiment of the present invention, and (b) a top view of a cavity according to the embodiment of FIG. 8 compared with the one of the embodiment of FIG. 9(a).

[0075] FIG. 10: shows a burner block suitable for the present invention, (a) perspective cross-sectional view, (b) and (c) top cross-sectional views of two embodiments of burner blocks suitable for the present invention.

[0076] FIG. 11: shows a top cross-sectional view of (a) a burner block suitable for the present invention, and (b) the same burner block with a burner mounted therein.

[0077] FIG. 12: Compares the variation, LT, of a section of the longitudinal wall of a forehearth according to the prior art measured along the longitudinal direction, X1, (a) at room temperature (RT), and (b) at service temperature (hT).

[0078] FIG. 13: Compares the variation, LT, of a section of the longitudinal wall of a forehearth according to the present invention measured along the longitudinal direction, X1, (a) at room temperature (RT), and (b) at service temperature (hT).

DETAILED DESCRIPTION OF THE INVENTION

[0079] As illustrated in FIG. 7, a glass fibre manufacturing plant according to the present invention comprises a forehearth (31) forming a passage for conveying molten glass (30) and defined by: [0080] a first and second opposite longitudinal walls (31L) having a hot longitudinal wall surface facing said passage and extending along a longitudinal direction, X1, having a longitudinal wall thickness extending along a first transverse direction, X2, normal to X1, and having a longitudinal wall height extending along a second transverse direction, X3, normal to both X1 and X2, [0081] a ceiling (31T), [0082] a bottom floor (31B) and [0083] an end wall (31E).

[0084] As can be seen in FIGS. 1 to 6, each longitudinal wall is made of a refractory masonry comprising: [0085] (a) a series of refractory base bricks (32) forming a base wall comprising a top surface for supporting, [0086] (b) two spacer bricks (23) lying on the top surface of the base wall and separated from one another at the level of the hot longitudinal wall surface by a distance, Wc, measured at room temperature (RT) along the longitudinal direction, X1, each spacer brick having a cuboid geometry comprising a hot surface (23H) forming a portion of the hot longitudinal wall surface, wherein, [0087] (c) a lintel (25) of length, WL>Wc, measured along the longitudinal direction, X1, at room temperature and comprising two opposite ends, each resting on one surface of one of the two spacer bricks, thus defining with the top surface of the base wall and the two spacer bricks, [0088] (d) a cavity (28) of width, Wc, and height, H1c, measured at the level of the hot longitudinal wall surface at room temperature along the longitudinal direction, X1, and along the second transverse axis, X3, respectively, and of depth, Dc, measured at room temperature along the first transverse axis, X2, [0089] (e) a support block (20) comprising a hot cuboid portion having a cuboid geometry of width, w, and height, h, measured along X1 and X3, respectively, at the level of the hot longitudinal wall surface at a service temperature, hT, of the forehearth of at least 1000 C., and of depth measured along X2 at least equal to D, wherein w<Wc, and h<H1c, said hot cuboid portion being reversibly inserted in the prismatic cavity, and [0090] (f) a gap surrounding the hot cuboid portion of the support block when positioned in the cavity, said gap being filled with a resilient material (29).

[0091] A cuboid geometry is defined as a convex polyhedron bounded by six quadrilateral faces, whose polyhedral graph is the same as that of a cube. A cuboid bounded by six rectangular faces, with each pair of adjacent faces meeting in a right angle is herein referred to as a rectangular cuboid. This more restrictive type of cuboid is also known as a right cuboid. In other words, if not rectangular, a cuboid may for example be bounded by two or more trapezia. A support block suitable for the present invention preferably has a hot cuboid portion wherein each pair of adjacent faces meet in a right angle. The hot cuboid portion is preferably, but not necessarily, of rectangular cuboid geometry. Indeed, it may also have a slightly tapered geometry with smallest dimensions at the level of the hot longitudinal wall surface, with width, w, and height, h, With such tapered geometry, the insertion into and withdrawal out of a cavity similarly tapered of a support block can be facilitated.

[0092] The gist of the present invention consists of a spacing element provided in the masonry which hinders the thermal expansion of the two spacer bricks, such that the distance, Wc, between said two spacer bricks measured at room temperature measured along the longitudinal direction, X1, at the level of the hot longitudinal wall surface cannot be reduced below a predetermined hot cavity width, W, at said service temperature, hT, wherein said predetermined hot cavity width, W, is larger than the width, w, of the hot cuboid portion of the support block. The gap left between the hot cuboid portion of the support block and the walls defining the cavity is filled with a resilient material (29) made of refractory material.

[0093] In an embodiment illustrated in FIG. 1, [0094] (a) The top surface of the base wall forms a planar surface along a base plane (X1, X2), [0095] (b) The two spacer bricks (23) are characterized in that, [0096] two opposite edges remote from the base plane and extending in the first transverse direction, X2, are cut off to form a right step at each of said two opposite edges, defining a recessed surface (23R) parallel to the base plane, and a stepping surface (23S) extending parallel to X3, [0097] at the service temperature (hT) the hot surface has a height, H2, measured along the second transverse direction, X3, and a height, H1, measured from the base plane (X1, X2) up to the recessed surfaces, the stepping surfaces (23S) of the steps thus having a height, HS=H2H1, [0098] (c) the two opposite ends of the lintel (25) each rests on one recessed surface (23R) of one of the two spacer bricks.

[0099] A right step is defined herein as a step characterized by two planar surfaces, a recessed surface (23R) and a stepping surface (23S), normal to each other. The recessed surface (23R) is substantially parallel to (X1, X2) and the stepping surface (23S) is substantially parallel to (X2, X3).

[0100] In this configuration, the spacing element is formed by the lintel (25) resting on the recessed surfaces (23R) and resisting the thermal expansion of the two spacer bricks which stepping surfaces abut against the lintel. The width, WS, of a right step on either side of a spacer brick is therefore about (WLWc), measured along the longitudinal axis, X1, at room temperature.

[0101] As illustrated in FIGS. 12(a) and 13(a), the masonry of a longitudinal wall is built at room temperature (RT). FIG. 12 illustrates a longitudinal wall section of a traditional forehearth of the prior art and FIG. 13 illustrates a corresponding longitudinal wall section of a forehearth according to the present invention. Upon heating the forehearth to service temperature, hT, of at least 1000 C., generally of the order of 1150150 C., all the bricks, lintels, etc. of a longitudinal wall (collectively referred to a longitudinal wall components) expand along the three directions, X1, X2, and X3. The most critical expansion component for maintaining the removability of a support block from the longitudinal wall at service temperature, hT, is the longitudinal expansion, L, along the longitudinal direction, X1. As illustrated in FIGS. 12(b) and 13(b), the longitudinal expansion, L=LT, wherein is a mean coefficient of expansion of the longitudinal wall's components. The longitudinal wall must be allowed to expand relatively freely, lest pressure concentrations may develop leading to the misalignment of the longitudinal wall's components, which would form an arched longitudinal wall or, worse, the collapse of some of the longitudinal wall's components. Open joints are usually distributed at regular intervals along the longitudinal wall to absorb the longitudinal expansion, L, of the order of 5 to 20 mm, of sections of the longitudinal wall.

[0102] As can be seen in FIG. 12(b), as the longitudinal wall components expand, they will absorb any gap of width, wg0, left during the building at room temperature between two adjacent bricks, and start pushing chain-wise the adjacent components, reducing such gaps to a width at service temperature, wg10. As a result, the longitudinal walls components which are adjacent to one another along the longitudinal direction are in tight contact with one another forming a compact line of components with substantially no gap between two components. The same applies to the support blocks (20) which are sandwiched in tight contact between two adjacent spacer bricks (23) and cannot be removed from the longitudinal wall at service temperature (hT).

[0103] By contrast, as can be seen in FIG. 13 illustrating an embodiment of a longitudinal wall according to the present invention, the thermal expansion of the spacer bricks (23) does not bring them into contact with the support blocks sandwiched therebetween, because the expanding spacer bricks contact the spacer elements first (in FIG. 13(b) the lintels (25) act as spacer elements), It follows that the gaps, wg0, between a support block (20) and adjacent spacer bricks (23) at room temperature are not reduced to a gap width, wg1, at service temperature (hT), which is close to zero, as is the case in the prior art (cf. FIG. 12(b)), but are merely reduced to a positive gap width, 0<wg1<wg0 (cf. FIG. 13(b)). It follows that the support blocks (20) can be withdrawn from between two spacer bricks (23) even at service temperature (hT). As discussed later, the resilient material (29) serves here inter alia to seal the gaps, wg1, left at service temperature (hT) between a support block and adjacent spacer bricks.

[0104] This has an enormous advantage in that it is not necessary to cool the forehearth, nor to dismantle the masonry surrounding a support block to exchange an old support block with a new one, operation that may last at least one week during which time the forehearth activity is interrupted. The support block in a forehearth according to the present invention can be exchanged at service temperature, without any dismantling of the bricks forming the masonry surrounding the support block. The exchange of a support block in a forehearth of the present invention can be completed in half a day. Although the replacement of the support block per se may be completed in less than an hour, it is necessary, prior to resuming a full volume production rate, to allow time for the forehearth to recover stationary thermal and pressure conditions, and to remove all dust of masonry and resilient material which may have fallen into the glass melt during the exchange.

[0105] A second embodiment of the present invention, showing an alternative spacing element, is illustrated in FIGS. 2&3. In this embodiment, which can be used instead of (cf. FIG. 2), or in combination with (cf. FIG. 3) the embodiment illustrated in FIG. 1 and discussed supra, comprises a base spacer (26) forming the spacing element. Said base spacer has a length equal to the predetermined distance, W, measured at said service temperature, hT, along the first longitudinal direction, and it lies on the top surface of the base wall between the two spacer bricks, such that the distance, H1, measured at the service temperature along the second transverse direction, X3, between a top surface of said base spacer and the lintel is larger than the height, h, of the hot cuboid portion of the support portion. In this embodiment, the top surface of the base wall preferably forms a planar surface along a base plane (X1, X2).

[0106] In a variation of the embodiment illustrated in FIG. 2, an alternative embodiment illustrated in FIG. 4, the top surface of the base wall does not form a planar surface, but is crenelated, forming merlons (27) of length equal to the predetermined distance, W, measured at said service temperature, hT, along the first longitudinal direction. Said merlons separating two spacer bricks actually correspond to a base spacer (26) which is an integral part of the base wall, instead of being laid on top of said base wall. In this embodiment, the spacing elements are formed by the merlons (27), which abut against the lateral walls of the flanking space bricks.

[0107] In yet an alternative embodiment, illustrated in FIG. 5, the two spacer bricks (23) have a geometry similar to the one discussed with reference to FIG. 1, but upside down. They are characterized in that, [0108] two opposite edges adjacent to the top surface of the base wall and extending in the first transverse direction, X2, are cut off to form a right step at each of said two opposite edges, defining a recessed surface (23R) parallel to X1, and a stepping surface (23S) extending parallel to X3, [0109] measured along the second transverse direction, X3, at the service temperature (hT), the hot surface has a total height, H2, and a height, H1, measured down to the recessed surfaces, the step thus having a height, HS=H2H1,

[0110] As shown in FIG. 5, the top surface of the base wall forms a merlon (27) of height, HS, measured along the second transverse direction, X3, and of length such that when the merlon contacts the stepping surfaces of the two spacer bricks, the distance between said two spacer bricks measured along the longitudinal direction, X1, at the level of the hot longitudinal wall surface at said service temperature, hT, is equal to the predetermined distance, W. Alternatively, a base spacer (26) can form a merlon on top of a planar top surface of the base wall (not shown).

[0111] In this embodiment, the spacing element is formed by the merlon supporting the recessed surfaces (23R) of the two spacer bricks and resisting the thermal expansion of the two spacer bricks by abuting against the stepping surfaces (23S).

[0112] The embodiment, illustrated in FIG. 6, is a combination of the embodiments of FIGS. 1 and 5, wherein the four edges extending in the second transverse direction, X2, of the spacer bricks are cut off to form a right step at each of said four edges, defining two top recessed surfaces (23R) and two bottom recessed surfaces (23R), each parallel to X1, and corresponding to two top stepping surfaces (23S) and two bottom stepping surfaces (23s) each extending substantially parallel to X3. The thermal expansion of the two spacer bricks flanking the two lateral sides of the cavity is hindered, on the one hand, by the lintel resting on the two top recessed surfaces of the top edges and pressing on the top stepping surfaces and, on the other hand, by the merlon (27) formed at the top surface of the base wall and pressing on the bottom stepping surfaces.

[0113] Hindering the thermal expansion of the spacer bricks (23) both at the level of the lintel and at the level of the base wall (cf. for example, FIGS. 3 and 6) is advantageous as it ensures a better control of the cavity dimensions as a function of temperature. But preliminary tests have shown that excellent results were obtained also when thermal expansion was hindered only at the level of the lintel (cf. for example, FIG. 1) or of the base wall (cf. for example, FIGS. 2, 4, and 5).

[0114] At service temperature, hT, of at least 1000 C., the gap surrounding the hot cuboid portion of the support block when positioned in the cavity has an average width, wg1, defined as wg1=(Ww), measured along the longitudinal direction, X1, which Is preferably comprised between 1 and 5 mm, and is preferably equal to 31 mm. This means that once the spacer bricks flanking either sides of the cavity have thermally expanded as the temperature reached the service temperature, hT, the cavity has a width; W, at the level of the hot longitudinal wall surface, which is still approximately 62 mm larger than the width, w, of the hot cuboid portion of the support block, at service temperature, hT ((w+4 mm)W(w+8 mm)). The support block may be slightly misaligned with a gap on one side of the support block being wider than the gap on the other side of the support block. To enhance alignment of the support block in the cavity, guiding ridges may be provided either on the surfaces of the hot cuboid portion of the support block, or on the walls defining the cavity. Alternatively or additionally, matching surfaces may be provided at the level of the cold surfaces (23C) of the spacer bricks, which are substantially colder, between the spacer bricks, lintel and support block, to ensure that the support block is well aligned, as shown for example in FIG. 11.

[0115] Similarly, at service temperature, hT, the gap surrounding the hot cuboid portion of the support block when positioned in the cavity has an average height, hg, defined as hg=(H1h), measured along the second transverse axis, X2, which Is preferably comprised between 1 and 5 mm, and is preferably equal to 31 mm. This means that once the whole masonry defining the cavity as well as the spacer block have thermally expanded as the temperature reached the service temperature, hT, the cavity has a height, H1, at the level of the hot longitudinal wall surface, which is still approximately 62 mm larger than the height, h, of the hot cuboid portion of the support block, ((h+4 mm)H1(h+8 mm)). It is clear that if the hot cuboid portion of the support block simply rested on the bottom floor of the cavity, the gap height above the block would be substantially larger than the gap height below the block. Even with the presence of resilient material filling the gap, it is to be expected that resilient material would be pressed by the weight of the support block, which would eventually move down closer to the floor of the cavity. This is of course undesirable, as the position of the support block must not change during operation. Again, guiding edges may be provided on the floor of the cavity, or matching surfaces may be provided at the level of the cold surfaces (23C) of the spacer bricks, which are substantially colder, between the spacer bricks, lintel and support block, to ensure that the support block is well aligned.

[0116] In a preferred embodiment illustrated in FIG. 9, the cavity (28) has tapered walls, with a width, Wt, and/or with a height, H1t, measured at room temperature at the level of a cold surface (23C) of the spacer bricks, opposite the hot surface (23H), along the longitudinal direction, X1, and along the second transverse axis, X3, respectively, which is larger than the width, Wc, and height, H1c, measured at the level of the hot longitudinal wall surface, Wt>Wc and/or H1t>H1c. FIG. 9(b) compares top views of a cavity having parallel lateral walls as shown in FIG. 8 (top drawing) with a cavity having tapered lateral walls as shown in FIG. 9(a) (bottom drawing). At room temperature (RT), the spacer bricks (23) are separated from one another at the level of the hot longitudinal wall surface by a distance, Wc, regardless of whether the lateral walls of the cavity are parallel or tapered. At the opposite side of the hot longitudinal wall surface, however, defined by the cold surfaces (23C) of the spacer bricks, the spacer bricks are separated from one another by a distance, Wt, in case of tapered walls, wherein Wt>Wc. The tapered walls allow an easier and self-centred introduction of a support block into the cavity both at room temperature, RT, and at service temperature, hT. As shown in FIG. 9(a), the lintel may have a tapered surface defining a cavity height at the level of the cold surfaces of the spacer bricks which is larger than the height, H1, measured at the level of the hot longitudinal wall surface.

[0117] As shown in FIGS. 8 and 9, the resilient material (29) is preferably provided in the form of a sheet, which is wrapped around the four peripheral surfaces of the hot cuboid portion of the support block. The resilient material is preferably made of refractory fibres, typically alumina fibres, or fibres comprising at least 90 wt. %, more preferably at least 95 wt. %, most preferably at least 99 wt. % alumina. The resilient fibres preferably do not comprise more than 2 wt. % silica, and more preferably comprise no silica, as silica may form an eutectic with oxides of adjacent refractory bricks, which could contaminate the glass melt by sublimation at high temperatures. An example of resilient material supplied as a sheet which is suitable for the present invention comprises ceramic fibre paper such as supplied by Morgan Thermal Ceramics.

[0118] The resilient material contributes to the proper alignment of the support block within the cavity, but its principal task is to thermally insulate and fluidly seal the hot longitudinal wall surface from the opposite side of the wall defined by the cold surface of the spacer bricks. Absent the resilient material filling the gap, heat from the forehearth passage would be lost through the gaps of the numerous cavities flanking said passage, creating an unacceptable thermal draft through the gaps in the longitudinal walls and disrupting the temperature and pressure control of the passage.

[0119] The support block may be anyone among one of the following: [0120] (a) A burner block for supporting a burner, preferably an oxy-burner; [0121] (b) A measurement block for supporting a pressure or temperature measuring device; [0122] (c) A peep hole block for supporting a viewing device for observing the passage; [0123] (d) A camera block for supporting a camera for taking pictures or videos of the passage, [0124] (e) An injection block for supporting a gun for injecting a fluid at a predetermined location of the passage; or [0125] (f) An atmospheric beam, for controlling the gas flows within the passage

[0126] Of all the above types of support blocks, burner blocks are of particular interest because a typical forehearth may comprise several hundred of such burner blocks aligned on each longitudinal wall. As shown in FIGS. 8 to 11, a burner block suitable for the present invention may comprise a cold surface (20C) and a hot surface (20H) opposite the cold surface. The cold surface is connected to the hot surface by a through-passage extending along a passage axis, Xp. As shown in FIG. 10(a), the through-passage comprises three portions: [0127] (a) A burner portion (21B), opening at the cold surface, and having a cross-section suitable for accommodating a burner (1) having a body and a downstream end portion (1D) characterized by a large base adjacent to the body, and ending at a small base having a cross-section smaller than the cross-section of the large base; [0128] (b) A flame portion (21F), opening at the hot surface and converging along the passage axis, xp, in the direction of the cold surface until meeting [0129] (c) A joining portion (21J), fluidly joining the flame portion with the burner portion in which it opens with a cross-section of dimensions comprised between the one of the large base and the one of the small base.

[0130] A support block and, in particular a burner block, is preferably made of a refractory material composed of at least 95 wt. % alumina, more preferably of at least 99 wt. %. The refractory material of the support block preferably comprises less than 10 wt. % silica, more preferably comprises less than 5 wt. % silica, most preferably comprises less than 2 wt. % silica. The bricks surrounding the cavity may be made of mullite, preferably of alumina enriched mullite.

[0131] As shown in the top views along a plane (X1, X2) of FIG. 10(b)&(c), the passage axis, Xp, forms an angle, , with the longitudinal direction, X1, comprised between 30 and 90, preferably, between 45 and 90. In FIG. 10(b), a burner block having a passage axis, Xp, forming an angle, =90, is illustrated, such that the passage axis, Xp, is parallel to the first transverse direction, X2. In FIG. 10(c) an alternative embodiment with a angle, <90, is illustrated, the burner preferably pointing in the direction of the flow of molten glass.

[0132] A support block suitable for the present invention and, in particular, a burner block preferably further comprises a cold cuboid portion comprising a cold surface (20C) opposite the hot surface (20H). The cold cuboid portion is coupled to the hot cuboid portion. The cross-sectional area normal to the first transverse axis, X2, of the hot cuboid portion is smaller than the one of the cold cuboid portion. The cold cuboid portion is adjacent to the cold surfaces of the flanking spacer blocks and they are not exposed to high temperatures. Consequently their geometries remain more stable during the heating up of the forehearth and can be controlled more accurately to ensure that the cold cuboid portion of the support block matches the cavity surfaces adjacent the cold surfaces of the spacer blocks. This way, a support block can be fixed to its predefined service position with a better control of the gap width and height around the hot cuboid portion of the support block.

[0133] The cold cuboid portion of a support block may comprise one or several surfaces which are coplanar with peripheral surfaces of the hot cuboid portion. For example the burner block represented in FIG. 10(a) comprises three surfaces coplanar with the hot cuboid portion: the bottom surface and the two lateral surfaces. The cold cuboid portions of the burner blocks represented in FIGS. 8 and 9(a) only have the bottom surface which is coplanar with the bottom surface of the hot cuboid portion. In yet an alternative embodiment, none of the surfaces of the cold cuboid portion is coplanar with any of the peripheral surfaces of the hot cuboid portion.

[0134] As shown in FIG. 10(b)&(c) and in FIG. 11(b), an oxy-burner is a burner comprising a body extending along the passage axis, Xp, and enclosing a fuel line (1F) and an oxygen line (10x) separate from the fuel line, both fuel line and oxygen line having a separate outlet at or adjacent to a downstream end (1D) of the body of the oxy-burner. The downstream end of the oxy-burner body has a cross section decreasing with the distance from the body; often the downstream portion has a conical or trunco-conical geometry. The downstream end can be mounted in the burner portion (21B) of the burner block, with the downstream end being located partly in, or adjacent to the joining portion (21F) and being oriented towards the passage of the forehearth. The present invention is particularly adapted for burner blocks supporting an oxy-burner (1) because since the flame of an oxy-burner reaches temperatures much higher than traditional air-burners, the burner blocks wear more rapidly and need changing more regularly. To date, the only two options available when a burner block is damaged is either to condemn it and let one spot without burner during production with the consequent temperature drop at the area surrounding the condemned burner block, or stop production in the forehearth passage concerned, dismantle the wall surrounding the condemned burner block, build a new wall section with a new burner block, and re-heat the forehearth passage to service temperature, hT, The latter option requires production to be interrupted for at least one week.

[0135] The downstream ends of the oxi-burners are usually partially engaged into the joining portion (21F) of the burner blocks and thus exposed to the service temperature, hT, in the forehearth. As long as fuel and oxygen flow through the corresponding lines, the downstream ends of the oxy-burners are cooled and kept at a safe temperature. In case of an accidental disruption of the flow of either fuel or oxygen, however, the downstream ends are not cooled anymore and they can get thermally degraded by exposure to the service temperature, hT. For this reason, the downstream end of an oxy-burner can be fluidly cooled with a cooling unit (3). As illustrated in FIG. 11(b). such cooling unit (3) may comprise: [0136] a cooling plate made of a thermally conductive material, defined by a first and a second main surfaces separated by a thickness of said cooling plate, and by an aperture extending through said thickness and having a geometry matching the geometry of the downstream end of the oxy-burner to form a thermal contact therewith; and [0137] a cooling channel defined by walls and comprising an inlet and an outlet for circulating a refrigerating fluid, in thermal contact with the cooling plate.

[0138] Generally, each longitudinal wall comprises at least two cavities (28), each cavity containing a support block (20) reversibly engaged therein. In case of burner blocks, each longitudinal wall comprises dozens, even hundreds of burner blocks. The at least two cavities are aligned horizontally and separated from one another by at least one spacer brick (23). It is preferred that the at least two cavities of the first longitudinal wall face the at least two cavities of the second longitudinal wall in a staggered arrangement. The end wall is likely preferably also provided with a cavity containing a support block (20) reversibly engaged therein.

[0139] A forehearth according to the present invention is greatly advantageous over forehearths of the prior art. As discussed above, in case a burner block is thermally damaged, instead of at least one week of interruption of the production in a forehearth of the prior art, a burner block can be changed in a forehearth according to the present invention with less than half a day interruption of the production: about a quarter of to half an hour to remove the damaged burner block, clean the cavity and replace the burner block by a new one, and a couple of hours to restore the thermal and pressure conditions disrupted during the change, as well as to give time to the glass melt to evacuate any dust from the refractory bricks and resilient material that may have fallen into the melt during the changing operation.

[0140] Other kinds of support blocks, such as a measurement block, a peep hole block or camera block, an injection block; or an atmospheric beam, for controlling the gas flows within the passage, may not be numerous and may not be exposed as intensely to thermal damages as burner blocks, in particular for supporting oxy-firing burners, but their positions may be required to vary more often depending on the actual behaviour of the forehearth, which may deviate from the expected behaviour, and thus may require such support blocks at other positions than initially planned. Of course, with an interruption of at least one week with prior art forehearths, it would be excluded to change the position of a support block only to get a hopefully better position. With a forehearth according to the present invention, on the other hand, the position of such support blocks may be changed more easily.

[0141] A support block can be reversibly loaded in a forehearth of a glass fibre manufacturing plant as discussed supra, by a method comprising: [0142] (A) building a forehearth as defined supra and illustrated in FIG. 7, forming a passage for conveying molten glass (30) and defined by: [0143] a first and second opposite longitudinal walls (31L) having a hot longitudinal wall surface facing said passage and extending along a longitudinal direction, X1, having a longitudinal wall thickness extending along a first transverse direction, X2, normal to X1, and having a longitudinal wall height extending along a second transverse direction, X3, normal to both X1 and X2, [0144] a ceiling (31T), [0145] a bottom floor (31B) and [0146] an end wall (31E), [0147] wherein building each longitudinal wall comprises: [0148] (a) laying a series of refractory base bricks (32) to form a base wall comprising a top surface, [0149] (b) laying two spacer bricks (23) onto the top surface of the base wall, separated from one another at the level of the hot longitudinal wall surface by a distance, Wc, measured at room temperature (RT) along the longitudinal direction, X1, each spacer brick having a cuboid geometry comprising a hot surface (23H) forming a portion of the hot longitudinal wall surface, [0150] (c) providing a lintel (25) of length, WL>Wc, measured along the longitudinal direction, X1, and comprising two opposite ends, and laying each of the two opposite ends onto one of the two spacer bricks, thus defining with the base wall and the two spacer bricks a cavity (28) of width, Wc, and height, H1c, measured at the level of the hot longitudinal wall surface at room temperature along the longitudinal direction, X1, and along the second transverse axis, X3, respectively, and of depth, Dc, measured at room temperature along the first transverse axis, X2, [0151] (d) providing and installing a spacing element that hinders the thermal expansion of the two spacer bricks, such that the distance, Wc, between said two spacer bricks measured at room temperature along the longitudinal direction, X1, at the level of the hot longitudinal wall surface cannot be reduced below a predetermined distance, W, at a service temperature, hT, of the forehearth of at least 1000 C., [0152] (B) providing a support block (20) comprising a hot cuboid portion having a cuboid geometry of width, w, and height, h, measured along X1 and X3, respectively, at the level of the hot longitudinal wall surface at a service temperature, hT, of the forehearth of at least 1000 C., and of depth measured along X2 at least equal to D, wherein w<W<Wc, and h<H1c<H1, said hot cuboid portion comprising four peripheral surfaces meeting two by two at ridges extending transverse to the first longitudinal direction, X1, [0153] (C) as illustrated in FIGS. 8 and 9(a), coating the four peripheral surfaces of said hot cuboid portion with a layer of resilient material (29), preferably in the form of a sheet, and [0154] (D) reversibly inserting into the cavity the hot cuboid portion of the support block, which peripheral surfaces are coated with the resilient material.

[0155] FIG. 8 illustrates the method defined supra with a burner block seen from the passage of the forehearth, i.e., looking at the hot surfaces of the spacer bricks (23), whilst FIG. 9(a) illustrates the same method seen from the opposite side of a longitudinal wall, looking at the cold surfaces (23C) of the spacer bricks (23). The cavity illustrated in FIG. 9(a) has tapered walls as discussed supra, to facilitate insertion and removal of a support block.

[0156] Once in place in a cavity, a support block can easily be removed therefrom as follows: [0157] (E) removing the support block from the cavity by sliding the hot cuboid portion along the first transverse axis, X2, [0158] (F) removing any resilient material left in the cavity, [0159] (G) reversibly inserting into the cavity the hot cuboid portion of a new support block as defined in (B), which peripheral surfaces are coated with the resilient material.

TABLE-US-00001 REF DESCRIPTION 1 burner or oxy-burner 1D downstream end of oxy-burner 1F Fuel line of oxy-burner 1Ox oxygen line of oxy-burner 20 burner block 20C cold surface of burner block 20H hot surface of burner block 21B burner portion of through-passage 21F flame portion of through-passage 21J joining portion of through-passage 23 spacer brick 23C cold surface of spacer brick 23H hot surface of spacer brick 23R recessed surface of spacer brick 23S stepping surface of spacer brick (parallel to X3) 25 lintel 26 base spacer 27 merlon formed by top surface of base wall and separating the spacer bricks 28 cavity 29 resilient material 30 molten glass 31 passage 31B passage bottom floor 31E passage end wall 31L passage longitudinal wall 31T passage ceiling 32 base brick h height of the hot cuboid portion of the support block H1 height of the cavity measured at service temperature, hT, at level of hot longitudinal wall surface H1c height of the cavity measured at room temperature, RT, at level of hot longitudinal wall surface H1t height of the cavity measured at room temperature, RT, at level of cold longitudinal wall surface in cavity having tapered walls H2 total height of the space brick measured at service temperature, hT H2c total height of the space brick measured at room temperature, RT hg height of the gap between support block and cavity measured at service temperature (hT), hg = H1 h Hs height of stepping surface measured at service temperature, hT, Hs = H2 H1 W hot cavity width at level of hot longitudinal wall surface at service temperature w width of the hot cuboid portion of the support block W2 cavity width at level of cold surfaces of spacer bricks along X1 at service temperature Wc cavity width at level of hot longitudinal wall surface at room temperature Wg1 width of the gap between support block and cavity measured at service temperature (hT), wg1 = W w Wh cavity width at level of hot longitudinal wall surface at service temperature for prior art cavity (unrestrained thermal expansion of spacer bricks). WL lintel length in the longitudinal direction, X1 Wt cavity width at level of cold longitudinal wall surface at room temperature in cavity having tapered walls Wh = (Wc Wh) = unrestrained thermal expansion W = (Wc W) = restrained thermal expansion