The Impact of Bubble Arrays On Glass Flow and Redox State of Glass During Glass Melting
The Impact of Bubble Arrays On Glass Flow and Redox State of Glass During Glass Melting
The Impact of Bubble Arrays On Glass Flow and Redox State of Glass During Glass Melting
Laboratory of Inorganic Materials of the Institute of Inorganic chemistry ASCR and the Institute of Chemical Technology,
Technická 5, 166 28 Prague, Czech Republic
E-mail: [email protected]
The bubble arrays present in the glass melting spaces may extract gases from the melt and thus decrease its refining ability,
as well as influence glass flow by changing density of the mixture glass melt-bubbles. Both phenomena were examined using
the 3D and 2D models. The examination of the bubble extraction ability on elected glass pathways in the 3D model has shown
that refining gases were evidently removed from the reduced glass melt (amber) while the concentration drop of dissolved
refining gases in an oxidized glass was negligible. The distinct bubble stirring effect in the 2D melting space was observed
when inputting about 3 vol.% of small bubbles (a = 2.5 × 10-4 m) through a part of bottom. The effect of bubble concentration
gradients on the intensity of glass convection was analogical to the impact of temperature gradients on glass flow in case of
temperature convection. Different behavior was observed, however, when examining the impact of geometrical shape on the
melt flow. Both described phenomena should be considered in advanced mathematical models of glass melting spaces.
In the 3D modeling, the rectangular melting space A typical picture of extraction of the dissolved SO2
with throat was 16.5 m long and 4 m wide. The glass from the flat glass melt containing sodium sulfate as the
melt layer thickness was 1 m. The temperature fining agent along 4 glass trajectories is plotted in figure
maximum 1500 °C was at X = 5.5 - 6.5 m and the throat 1a, the similar dependence valid for the same glass
was 10.5 m located from the front wall. When studying containing sulfides (amber glass) is presented in figure
the bubble and glass flow interference, the 2D model 1b. The concentration drops in figure 1a corresponds to
melting space 1 × 1 m was chosen for most calculations. short residence times of glass in the high temperature
The bubbles entered the space by the central part of the region near the glass surface. The repeated con-
bottom. The glass was the soda-lime-silica glass centration steps express the glass circulation in the
containing 74 wt.% SiO2, 16 wt.% Na2O and 10 wt.% melting region. The concentration of the dissolved SO2
CaO. The glass melt was refined by the sodium sulfate. decreased along all pathways examined, nevertheless,
The glass temperature as well as velocity fields and the maximum concentration drop did not exceed
subsequently, the redox distribution and bubble 3 mol m-3. In the reduced glass, on the contrary, the
distribution in the space were calculated using the above bubble extraction ability is much higher attaining up to
mentioned partial models. The bubble impact on the tens of mols of SO2 per m3 as shown in figure 1b.
redox state of glass was examined along glass melt
pathways through the melting space. The pathways have
started under the glass batch blanket and finished in the
throat. The local values of the bubble number density,
gas concentrations in the melt and in bubbles were used
to calculate the local mass flow of refining gases
between the bubbles present and the melt (see equation
(1) in [5]). The sum of concentration changes of
refining gases along elected pathways gave the
approximate concentration decrease of the refining
agent concentration in the melt owing to bubbles. The
accuracy of results was limited by the fact that the local
mass flow did not take into account the previous effect
of bubbles. The typical values of volume fractions of
bubbles in the melt were obtained also for usage in the
2D model. In the latter 2D model calculations, the bub-
bles of constant radii 2.5 × 10-4, 5 × 10-4 and 1 × 10-3 m
and in volume concentrations 0.2, 1, 3, 10, 20 and
30 vol.%, respectively, were used to calculate the a)
resulting bubble and glass velocity distribution in the
space. Bubbles entered the central part of the bottom
space and the fraction of bottom occupied by inputting
bubbles moved from 0.02 to 1, but in most cases was
fixed at 0.02.
The following calculations were executed to
elucidate the outlined problems:
The values of the glass volume occupied by probable. The appropriate dependencies are plotted in
bubbles in the 3D model may give an approximate figure 2.
information about bubble concentration gradients in The picture of a typical glass velocity distribution
the space. The concentration differences are the in the 2D space is presented in figure 3a, b. The bubbles
driving force of convection due to bubbles and help us entered the central part of the bottom, the fraction of the
to provide the 2D model with the appropriate input bottom occupied by inputted bubbles was X/Xo where Xo
values. The independent calculations of glass flow and was the space width. As is obvious from both figures,
bubble density distribution in the 3D model, however, the glass with bubbles rose through a relatively narrow
make the results only qualitative. The example of central vertical column to the glass level and then
the bubble distribution on two transversal straight lines reversed back to the bottom with a much lower velocity.
through the space show nevertheless both high The fraction of the bottom occupied by bubbles only
bubble concentrations and bubble concentration slightly influenced the character of the flow as the
gradients, particularly in the region of the temperature bottom backflow “swept” the inputting bubbles into the
maximum close to the glass surface. The impact of narrow rising column of glass at higher values of X/Xo
bubbles on glass flow appears therefore highly (see figure 3b). The characteristic glass velocity and the
a) a)
b) b)
Figure 2. The dependence between the volume concentration of Figure 3. The pictures of two typical glass velocity distribu-
bubbles, ϑ, and Y coordinate in the tranversal sections through tions in the 2D melting space 1 × 1 m. The length of arrows cor-
the 3D melting space; a) X = 1.5 m (under the batch blanket), responds to the distance run in the course of 10 s. At 1300 °C,
1: 0.2 m under the boundary glass batch - glass melt, 2: 0.5 m the initial bubble volume fraction, ϑo = 3 vol.%, the bubble
under the boundary glass batch - glass melt; b) X = 6.5 m (in the radius a = 5 × 10-4 m, τ = 50 hrs; a) the fraction of the bottom
temperature maximum), 1: 0.2 m under the glass level, 2: 0.5 m occupied by inputting bubbles, X/Xo = 0.02; b) the fraction of
under the glass level. the bottom occupied by inputting bubbles, X/Xo = 0.5.
ρgl - ρbub, and the reciprocal value of kinematical therefore influence the resulting redox state of glass
viscosity of glass, 1/υ, on the average characteristic only very slightly. The reciprocal temperature de-
glass velocity are plotted in figure 11. pendence of sulfides stability, on the contrary, shifts the
production of SO2 and consequently, the SO2 extraction
DISCUSSION by bubbles, towards lower temperatures. That is why
the bubble extraction ability along predominantly low
The temperature stability of sulfates and sulfides in temperature pathways is high. The concentration drop
the glass is responsible for the different bubble distribution for 40 trajectories examined exhibits the
extraction ability in the oxidized glass melts with the maximum frequency at ∆c ∈ 〈40;45〉 (mol m-3) (see
sodium sulfate and in the reduced glass containing figure 12b). As the concentration of the refining agent
sulfides. As sulfate ions decompose apparently only in the melt is of the same order of magnitude as ∆c, the
above 1400 °C, the small part of glass trajectories is distinct influence of bubbles on the redox state of glass
exposed to gas diffusion into extracting bubbles and in reduced glasses containing sulfides can be expected.
consequently, the concentration decrease of sulfates is The glass flow intensity and bubble concentration
low. Figure 12 a presenting the concentration difference distribution acquired from the 2D model show that even
distribution for the examined 40 trajectories shows the a small amount of bubbles entering the space stirs the
maximum frequency at ∆c ∈ 〈0;0.3〉 (mol m-3). The melt vigorously (see figures 3 and 4). It appears to be
bubble clouds in glasses containing sulfates should useful to compare the stirring effect of bubbles with an
ideal mixer in the same 2D space.
The bubble concentration change brought about by
the inputting bubbles is given by:
X
dϑ+ = uϑo dτ (1)
Xo
X
a) ϑ+ = ϑo [1 - exp(-uτ)] (3)
Xo