Glass Melting Technology: A Technical and Economic ... - OSTI

melter. Detailed designs were to be completed the next quarter, and tests were planned
for the second quarter of 2004.
The project team discussed the CFD modeling approach with the lead FLUENT glass
modeler, and an agreement was reached on a multi-step modeling approach. As soon as
the contract with Fluent is in place, the CFD work will begin, with GTI and the glass
companies providing melter and glass property data, respectively. By the end of year one
(September, 2004), an initial model was to be developed and evaluated by the project
team.
Physical modeling was also deemed to be crucial to understanding the melting system
and to increasing chances of success. A GTI engineer was assigned the task of designing
a physical model of the SCM unit. He will be assisted by engineers from Owens Corning
and Corning with extensive physical modeling experience. During the first quarter of
2004, the scaled, dimensionless-unit based, modeling approach was to be developed and
reviewed. Work in quarter two of 2004 was to focus on design and fabrication of the test
unit at GTI. By the end of year one, initial physical modeling results for the rectangular
melter using polybutene as a surrogate fluid was to be completed. Polybutene, at near
room temperature, has similar viscosity-temperature curves to those of molten glass
compositions.
Work has been initiated in a number of related, and important, areas. First, literature
searches continued. Part of this was contracted to Prof. Pioro so a full history of SCM
development and theory of the technology would be available. Other literature reviews
involved studying world literature, and translating from Russian and other languages,
relevent papers. Second, plans were initiated to examine several phenomena that could
impact on glass melting in the SCM unit. These include devitrification caused by the
externally-cooled walls and metal contamination caused by contact of molten glass with
the metal walls. Crucible tests will be designed and carried out by the glass company
partners. Literature will also be reviewed.
Communications and education are important to the success of this project. A website
will be established for faster communication between project team members, sponsors,
and interested parties. This site will be maintained by GTI with links to all member
organizations. The project team also agreed to visit Europe in the summer of 2004. They
visited several advanced European glass melters, the evaporative cooling on melters in
Latvia, and working SCM units for mineral wool production in Belarus. This trip was
combined with a European glass meeting to learn even more about advanced glass
melting activities.
Patents
GTI holds world-wide rights to the submerged combustion melting technology outside
the former Soviet Union. GTI also holds a patent covering portions of the technology. A
new patent covering the combustion system used for oxy-gas firing was in progress and
was expected to be filed in the next quarter.
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