CA1331282C - Heating vessel lid construction - Google Patents

Abstract

ABSTRACT
A lid of a glass batch melting vessel is subjected to corrosive and thermal degradation. The lid is cooled and the temperature of the exposed inner surface of the lid is controlled such that particulate and molten materials entrained in exhaust gas circulating within the vessel adhere to the lid surface forming a protective, insulating coating that prolongs the service life of the lid. In addition, a multilayered, cooled metal lid for a heating vessel has a main support plate fabricated from low carbon steel and a chromium steel overlay that is exposed to the hot interior portions of the vessel. The chromium steel overlay has a chromium content by weight of approximately 10 to 25 percent.

Description

1- ~331%82 HEATING VESSEL LID CONSTRUCTION
This application is a division of our application serial number 570,754 filed June 29, 1988.
Back~round of the Invention 1. Field of the Invention This invention relates to high temperature heating vessels, and in particular, to technique for prolonging the service life of a lid for a glass batch melting furnace by protecting the inner exposed surface of the lid. This invention also relates to a heat and wear resistant lid for a glass melting furnace.
2a. Technical Considerations One type of glass melting process entails feeding of glass batch materials onto a pool of molten glass contained in a tank type melting furnace and applying thermal energy to melt the materials into the pool of molten glass. The melting tank conventionally contains a relatively large volume of molten glass so as to provide sufficient residence time for currents in the molten glass to effect some degree of homogenization beore the glass is discharged to a forming operation.
U. S. Patent No. 4,381,934 to Kunkle and Matesa, disclcses an alternative type of glass melting arrangement, and more particularly an intensified batch liquefaction process in which large volumes of glass batch materials are efficiently liquefied in a relatively small liquefaction vessel. This type of process, particularly when using intensified heat sources such as oxygen flame : 1331282 burners, produces relatively small volumes of high temperature exhaust gases.
During the heating and melting process, it is believed that certain components of the batch material vaporize. These vapors may be corrosive to exposed metal and refractory surfaces and when combined with the hot exhaust gas stream that circulates through vessels of the type disclosed in U. S. Patent No. 4,381,934, corrode exposed interior surfaces, and in particular the vessel lid. In addition, the exhaust gas may entrain particulate matter within the vessel which may act as an abrasive on an exposed surface. This corrosive and abrasive gas stream greatly reduces the service life of the vessel lid which may result in increased costs and additional do~n time for lid repair and replacement.
Due to the corrosive effects of the exhaust gas stream within the vessel which are accelerated by the high temperatures as well as any abrasive or erosive effects from the entrained particulates, exposed surfaces within the vessel, and in particular the vessel lid, must be designed to withstand these deleterious conditions, so as to reduce maintenance and/or replacement of the lid that is necessitated by excessive wear along its inner surface~
The high temperatures within the vessel may also pose additional processing problems. For example, heat loss will affect the efficiency of the operation. The-more heat that is lost during the liquefaction process through uninsulated and/or exposed interior surfaces of . ~
133~ 282 the vessel, the less efficient the liquefaction process becomes. This may require additional heat input to the vessel in order to account for the amount of heat lost.
In particular, the removal of heat by cooling the vessel lid in order to reduce heat degradation and prolong service life reduces the overall heating efficiency of the operation. If this heat loss could be controlled and reduced, the overall efficiency of the operation would be increased.
It would be advantageous to have a heating vessel lid with a protective coating on its exposed inner surface that both insulates the lid, thus reducing heat loss from the heating vessell and protects the exposed inner surface from a high temperature corrosive gas stream entrained with abrasive particulates, so as to increase its service life and decrease overall operating costs. In addition, it would be advantageous to have a wear resistant lid design that could withstand such operating conditions and provide a prolonged operating life.
U. S. Patent No. 3,165,301 to Riviere teaches a method and device for protecting refractory walls. A
burner positioned in the roof of an elongated horizontal furnace flows a gaseous suspension of carbon particles along the roof to protect the roof against heat radiating from the flame formed by burners in the furnace. The carbon particle suspension is circulated within the furnace parallel to the roof and in a direction opposite to that of the main burner flame. The arrangement - 4 - ~ 3 3 1~ ~ 2 reguires additional gas to be added to the heating system~ Furthermore, the carbon particles are an additional contaminant in the heating operation.
U. S. Patent No. 4,021,603 to Nanjyo et al teaches a cooled metal roof assembly for an arc furnace with refractory liner to protect the interior roof surface from high heat. Fire brick or other refractory material is provided within grooves formed on the interior ~urface of the roof to improve r~sistance to heat of the furnace roof assembly. The refractory material must be periodically replaced in order to ensure proper thermal insulation. In addition, the center portion of the lid is a consumable substructure that includes three holes for electrodes.
There is no protection provided to this portion of the lid.
U. S. Patent No. 4,182,610 to Mizuno et al teaches a water cooled metal cover for steel making or smelting furnace. Fins in the formi of a lattice structure extend from the interior surface of an annular portion of the cover to provide a surface to which slag resulting from splashes within the furnace may adhere. The splashes of slag that adhere to the fins insulate the lower surface of the cover's cooling jacket. The center portion of the cover which includes openings for electrodes, does not have the lattice structure to accumulate the slag so that there is no protection provided on this portion of the lid. In addition, the random splashing of-the slag does ; not provide a uniform buildup of insulating material over the entire cover surface.

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.- ~ ., . ~ ~ , _ 5 _ ~ 3~2~2 U.S. Patent No. 4,434,495 to Tomizawa et al.
teaches a cooling pipe structure for arc furnaces.
Wherein cooling pipes are embedded within refractory blocks. The pipes are positioned adjacent to the surface of the block facing the inside of the furnace to intensify the cooling of the surface. Slag splashed against the block surface will congeal and adh~re to the block to form an insulating film.
U.S. Patent No. 3,765,858 to Settino teaches a method of roll forming a ribbon of glass at high temperatures by bringing the glass, while still molten, into con~act with a roll faced with an iron-based alloy which includes, among other components, 5.0 to 5.8 percent chromium by weight. The patent discloses other roll configurations wherein the rolls are provided with a surface of AISI type 410 or 420 stainless steel.
U.S. Patent No. 4,216,348 to Greenberger teaches a water cooled roof panel assembly for an electric arc furnace. Copper sheets are brazed to a steel backing having integral ducts to circulate cooling fluid through the panel. An outer ring around the roof assembly acts as both a water source and drain for the panels.
U.S Patent Nos. 4,182,610 to Nizuno et al. and 25 4,197,422 to Fuchs et al. teach a water cooled furnace ~ -cover having a plurality of cooling boxes or jackets that provide a ducting arrangement such that coolant may circulate through the cooling boxes to cool the ~urnace ~3~1282 cover. In Mizuno et al., fin-like members extend from the lower surface of the furnace cover so that a slag layer may adhere to the fins to form a heat insulating layer.
In Fuchs et al., a protective layer of refractory material is disposed on the underside of the cooling boxes to provide additional thermal protection for the cover.
U.S. Patent No. ~,453,253 to Lauria et al. teaches a wall and roof construction ~or electric arc furnaces that are made of graphite blocks with removably attached fluid cooled panels. The panels contain conduits for circulating a cooling fluid along the exterior surface of the block to cool it.
The prior art teaches lid construction furnaces but does not disclose controlling the cooling of the lid to permit materials entrained in hot gases circulating within the furnace to be deposited on the inner surface of the lid to form a relatively uniform and continuous insulating and protective layer herein thickness of the layer, and its associated insulative properties may be adjusted by varying the cooling of the lid. The prior art also does not teach a heat and wear resistant vessel lid that is subjected to high temperature, corrosive and abrasive conditions.
An object of this disclosure is to provide a protective layer on an exposed inner surface of a heating vessel. Hot exhaust gas which circulates within the -~
vessel includes entrained particulate and molten :~
materials, which may corrode and thermally degrade exposed "'','', ;
, ': ,~ ' `` ~3~ 32 surfaces within the vessel. The surfaces are cooled such that the particulate and molten material that contacts the surface will condense and stick to the surface.
Additional entrained material build up on previously deposited material so as to increase the material layer thickness. This layer both thermally insulates the sur~ace and protects it against corrosion from materials within the circulating exhaust gas stream. As the layer thickness increases, so does the insulative properties.
When the temperature within the heating vessel is suf~iciently high, newly deposited material on the layer will be melted off so as to maintain a relatively constant layer thickness over the surface. The cooling rate of the lid or the heating rate within the heating vessel may be varied in order to change the thickness of the built~up layer.
Another object is to provide a heating vessel lid with a controlled cooling arrangement that allows materials entrained in exhaust gas circulating within the vessel to be deposited on an inner surface of the lid and build up a protective, insulatlng layer.
The present disclosure also provides a heat and wear resistant lid for a heating vessel whose interior surface is subjected to high temperature, corrosive and abrasive conditions during the heating operation. A main support plate constructed ~rom ~or example, low carbo~
steel, is covered with a protective facing member to - 8 - 133128~
increase the use~ul operating life of the lid. The lid may be cooled so as to further reduce the deleterious accelerating affect the high temperature have on the corrosion of the lid.
In one particular embodiment of the invention, the protective member is constructed from a chromium containing alloy that is approximately 10 to 25 percent chromium by weight. The protective member may be a chromium steel alloy plate or weld overlay. The lid is cooled to maintain a member temperature between approximately 900F to 1200F (482C to 649C) so that entrained materials within the circulating exhaust gas adhere to and build up on the exposed surface of the member and ~orm an insulating and protective layer.
Chromium alloy steel is used for the protective member because of its high temperature and abrasive resistant characteristics as well as its resistance to oxidization and sulfidation.
Here also described is a lid module for a heating unit having a rigid support plate, a protective facing member overlaying the support plate and an arrangement to independently support each module, interconnect the module with adjacent modules, and cool each module. The protective member is a chromium containing alloy and may include a plurality of overlaying members.
Further described is a method of protecting an-- -exposed, inner surface of a heating vessel from corrosive gases. The exposed surface as provided with a protective .- : -~ 3312~2 _ 9 member whose temperature is maintained outside a range of a temperature range within which it will crack.
Embodiments of the i~vention will now be described with re~erence to the accompanying drawings wherein;
Figure 1 is a cross-sectional view of a liquefaction vessel including a lid with a protective insulating layer and embodying the invention.
Figure 2 is a graph showing the insulating properties of a cooled metal lid used in a liquefaction vessel as batch material adheres to the interior lid surface.
Figures 3, 4 and 5 are enlarged cross-sectional views of alternate embodiments of the present invention.
Figure 6 is a plan view of the expanded metal shown in the embodiment illustrated in Figure 5.
Figure 7 is a cross-sectional of an alternate liquefaction vessel embodying the present invention including a heat and wear resistant lid.
Figure 8 is an enlarged top view of a lid module for the heating vessel lid illustrated in Figure 7 with portions removed for clarity.
Figure 9 is a cross-sectional view through line 9-9 of Figure 8 illustrating the protective facing members, the batch build-up layer, the expanded metal anchors, the cooling ducts and hanger support arrangement.
Figure 10 is a cross-sectional view through line 10-10 of Figure 8 illustrating the lid module ~-;

133~ 2~2 interconnecting arrangement with portions removed for clarity.
Figure 11 is a view similar to Figure 10 illustrating an alternate embodiment of the invention.
Figur~ 12 is a view along line 12-12 of Figure 11 showing the exposed surface of the lid of the heating vessel illustrated in Figure 7.
petailed Description of the Preferred Embodiments This invention is suitable for use in a process wherein a hostile environment adversely ef~ects the exposed interior surface of a heating vessel~ It is particularly well suited for use in a heating process where high temperatures and additional conditions within the heating vessel such as circulation o~ corrosive and abrasive materials accelerate the wear of portions of the lid or roof o~ the heating vessel. The invention is described in connection with a glass liquefaction process of the type taught in U. S. Patent No. 4,381,934 to Heithoff but it is to be understood that the invention can y be used in any heat related process where heat loss is to be reduced or exposed surfaces such as heating vessel walls reguire an insulating and/or protective coating.
With reference to Figure 1, the liquefaction vessel 10 is of a type similar to that disclosed in U. S. Patent No. 4,381,934. The vessel 10 includes a steel drum 12 supported on a circular frame 14 which is in turn moun~ed ~or rotation about a generally vertical axis corresponding to the center line of the drum 12 on a plurality of . . - -,. i~ -:

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1331~82 support rollers 16 and aligning rollers 18. An outlet assembly 20 below the drum 12 includes a bushing 22 with an open center 24 leading to a collecting vessel 26. A
lid 28 is provided with stationary support by way of a circular frame 30 including lid support blocks 31. The lid 28 includes at least one opening 32 for inserting a burner 34. The burner 34 is preferably a ~ulti-port burner and is preferably fired with oxygen and gaseous fuel, such as methane, but can be any type of heat source that produces hot gases to heat batch material 36 within the vessel lO, e.g., plasma torches.
Within the vessel 10, a layer of unmelted batch 36 is maintained on the walls of the drum 12 encircling a ~ ;
central cavity within which combustio~ and liquefaction takes place. The heat from the flame of the burners 34 causes a portion 38 of the batch 36 to become li~uefied and flow downwardly through the bottom opening 24. The lique~ied batch 38 flows out of the liquefaction vessel 10 -~ ;
and may be collected in the vessel 26 below the 20 liquefaction vessel 10 for further processing as needed. ~ ~
The exhaust gases escape upwardly through an opening 40 in ~ -the lid 28 into an exhaust duct (not shown~ or through an ;~
opening in the bottom of the heating vessel (not shown).
During the liquefaction process in the vessel 10, various materials become entrained in the hot exhaust gas from the burners 34. For example, in a typical ~
soda-lime-silica batch these entrained materials may include vapors such as, but not limited to, sodium - 12 _ ~331~2 hydroxide and particulates such as, but not limitad to, sodium sulfate or sodium carbonate, all of which are highly corrosive to metal and refractory materials. At the elevated temperatures within the heating vessel 10 the chemical attack on exposed interior surfaces of the vessel 10 is accelerated. In addition, abrasive particles within the vessel 10 may combine with the hot exhaust gas to form a corrosive and abrasive gas stream that circulates within the vessel 10. The interior surface 42 of the lid 28 presents a large exposed surface within the vessel 10 that is susceptible to this high temperature attack.
In general, the surface 42 is made of a corrosive resistant steel such as, but not limited to, chrome alloy steel. Although not limiting in the present invention, in a praferred embodiment of the invention the lid 28 is preferably a fluid cooled metal lid as shown in ` Figure 1. A cooling fluid, for example air or water, enters the lid 28 through inlet 44 and flows into plenum 46. The fluid then passes through perforate plate 48 to distribute the cooling fluid along inner surface 50 of the exposed interior surface 42 of the lid 28. The fluid circulates along the inner surface 50 and exits the lid 28 through outlet 52. The arrows in Figure l show the circulation of the cooling fluid through the lid 28. As the fluid circulates through the lid 28 it extracts heat from the interior surface 42 so as to maintain a surface temperature of surface 42 lower than that of the interior of the vessel lO. The removal of excess heat through the . .

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lid 28 in order to main~ain a relatively low temperature of the lid 28 thus reducing heat degradation and prolonging its service life may result in an inefficient heating operation since additional heat must be added to the system in order to affect the amount of heat lost or removed.
In the embodiment of the invention illustrated in Figure 1, the surface 42 is cooled to a temperature such that material circulated by the hot exhaust gas within the ~0 vessel 10 will begin to adhere to it. In the initial stages of the vessel 10 heatup, the exhaust gas with the :~
vessel 10 may include, but is not limited to, entrained airborne particulates ~uch as sand grains, dolomite and limestone, molten sodium carbonate, and molten glass cullet particles. At a sufficiently low lid surface 42 temperature, material such as molten glass cullet and ;~
sodium carbonate will condense and '~freeze" on the lid ;~
surface 42 with additional glass cullet and sodium carbonate, as well other solid particulate materials and 20 condensed vapors, building up thereon. This built-up ~:~
layer 54 has a coef~icient of thermal conductivity at least an order of magnitude lower than the metal lid 28 and therefore provides an insulating effect so that more heat stays within the vessel 10 and less is removed through the cooled lid 2d. As the temperature within the vessel 10 increases due to less heat loss, additional ~~-particulates within the exhaust gas stream begin to soften and also stick to the previously deposited batch layer 54 s~ -~33~ 2~2 further increasing its insulating qualities. This in turn further reduces the heat loss through the lid 28 and increas~s the temperature within the vessel 10. In addition, unsoftened particulates are captured by the heat softenad layer, further adding to its thickness and insulative properties. At a sufficiently high temperature within the vessel 10, the deposited material in layer 54 will start to melt at the surface exposed to the interior of the vessel 10 and drip back into the vessel 10, thus limiting the thickness of the batch layer 54 buildup and maintaining it at a generally constant layer thickness, with a correspondingly reduced heat loss. At this steady ;~
state condition, the final batch layer 54 thickness will directly relate to the types of material being heated and the interior temperature within the vessel 10. As a result, it is clear that the relationship between the engineering of the vessel and type of material within the vessel 10 requires balancing the cooling of the lid 28 and the temperature within the vessel 10 so as to develop the layer 54 thickness required for a specific heating process.
It should be noted that the surface 42 should be of a material that is not early oxidized because the metal oxide may combine with the material in the layer 54 to ~orm an interface layer having a lower melting point than the layer 54. As a result the interface layer will be loosened from lid 28, and the layer 54 will fall back into the vessel 10 exposing the lid surface 42. In addition, if the metal does become oxidized care must be taken that ', ~ ' ' ~' .,- - ' ' ;' ~' .

- 15 - ~33~282 any oxides formed on the lid surface 42 will not add any color or any other detrimental contaminants to the resulting glass if the oxides become incorporiated into the glass.
The batch layer 54 thickness can be modified by changing the heating rate within the vessel 10 or the cooling rate of the lid 28. For example, if the amount of heat provided by the burners 34 is reduced, the layer thickness will increase since the temperature within the vessel lO would be lower, thus allowing the layer thickness to increase before the insulating properties of the layer raise the internal temperature of the vessel lO
to that required to melt the exposed outer surface of the layer 54. Conversely, by increasing the amount of heat provided by the burners 34 the thicXness of layer 54 can be reduced. As discussed, the thickness of the layer 54 can also be modified by changing the cooling rate of the :~
lid 28. Although not limited in the present invention, a valve 55 at inlet 44 may control the flow of cooling fluid in the lid 28 as shown in Figure l. In particular, by increasing the cooling rate, the amount of heat removed from the system through the insulating layer is increased ~:
thu~ cooling the layer 54 and allowing its thickness to increase until the increased insulating effect of the layer increases the internal temperature of the vessel to that required to melt the exposed surface of the layer~54.
The batch layer 54 provides several interrelated functions. The layer 54 protects the surface against ` ` 133~ ~82 abrasive particles circulating within the vessel. It is contemplated that some of the particulates will get "stuck" to the layer and become part of the layer 54 itself. The layer 54 further functions as an insulator that both reduces the heat loss within the heating vessel 10 through the lid 28, and lowers the temperature of the lid surface 42, thus reducing the effects of heat degradation. The layer 54 also seals the lid surface 42 and protects it from chemical attack. Specifically, the layer 54 provides a barrier between the surlace 42 of the lid 28 and oxygen, moisture, and corrosive vaporous gases that circulate within the vessel 10, such as, but not limited to, sodium sulfate, all of which will attack and corrode the lid surface 42. In addition, since chemical reactions are generally accelerated at high temperatures, the reduced temperature of the surface 42 of the lid 28, due to the insulating layer 54, reduces the rate of any chemical attack at the lid surface 42 by corrosive materials and thus prolonqs the lid life.
Figure 2 illustrates the effects on a lid of batch layer 54 buildup with respect to temperature and burner gas usage for a liquefaction vessel similar to that shown in Figure 1. In this example, the cooling gas was air. It should be noted that the reduction in the burner gas usage at elapsed time intervals of 30 minutes and 70 minutes was made to maintain a generally constant internal tempera~ure within the vessel 10 as the insulating layer 54 began to buildup on the lid. Referring to Figure 2 prior to the ,. - .~ , .~, ,: - ., ..... ~ . , . :, . " - -: - i, - ~ -. .

17 13~1282 batch buildup on the lid, the metal temperature was approximately 1140F ~616C), cooling gas enthalpy was approximately 115 x 103 BTU's per hour, cooling air exit temperature was approximately S50F (291~C) and the burner gas usage was approximately 90 cubic feet per hour (CFH) at approximately 85F (29JC) ambient temperature. After about 100 minutes of allowing the batch layer to build up on the lid, these values were 825F (441C), 6.5 x 103 BTU's per hour, less than 400~F (204C) and ~0 CFH, respectively. As can be seen, the lid metal temperature, cooling gas enthalpy, and cooling gas exit temperature were all significantly reduced due to the batch layer buildup on the lid. It is believed that the two peaks in the metal temperature of the lid at elapsed times 55 15 minutes and 85 minutes as shown in Figure 2 may have been ;~
due portions of the built up layer falling off of the lid surface 42 and the subsequent restabilization of the lid temperature. In general, it is expected that maintaining ~-a lid sur~ace 42 temperature of approximately 900F~150F
(481C+66C) in a liquefaction vessel 10 with an internal vessel temperature sufficient to liquefy a typical soda-lime-silica glass batch, will form an insulating and protective layer between 1/8 inches to 3/4 inch (0.32 cm to 1.91 cm) thick depending on heating and cooling conditions and batch formulation.
As the layer 54 increases in thickness, it is ~
possible that a portion of the layer 54 may fall off exposing an area of the interior surface 42 of the lid .

- 18 - ~ 3 3 ~ 2 ~ 2 28. As a result, there may be a kemporary loss of insulating effect requiring sudden change in heating and cooling demands. This may lead to dif~iculty in ?
controlling internal vessel temperature and the amount of 5 coolant required for the lid 28. I* desired, the surface 42 of the lid may include anchoring devices such as, but not limited to, grooves 56 to accommodate and hold the batch. The grooves 56 may be on the order of 3/32 inches (0.24 cm) deep. Referring to Figure 3, although not 10 limiting to the invention, the grooves 56 may be dovetailed in shape to help secure the batch layer 54 to the surface 42. The groovas 56 also provid~ additional surface area for initial layer 54 built up and may distribute and reduce surface-to-surface shearing ~orces 15 between the layer 54 and lid surface 42 due to temperature change in the vessel 10. Referring to Figure 4, the initial adhesion of the lid 54 to the surface 42 may be enhanced by coating the surface 42, whether it be smooth or grooved, with a refractory cement 58 which provides an 20 initial insulation in the vessel 10 and better adhesion of the layer 54 due to the resulting higher temperature formation of the initial portions of the layer 54.
Figures 5 and 6 illustrate an additional embodiment o~ the present invention. In order to further anchor 25 layer 54 to lid 28, foraminous members 62, such as expanded metal, perforated plates, or screening are secured to surface 42 of the lid 28. The foraminous members 62 must be heat resistant and adequately attached . ~ ... .

~L331282 to the 28 so as to help support ~he layer 54 as it builds on the lid surface 28. Although not limiting in the present invention Figure 6 illustrates an expanded metal -configuration that may be used. In one particular embodiment of the invention, No. 16 expanded metal fabricated from 410 stainless steel is tack welded at approximately 2 to 3 inch centers (5.08 to 7.62 cm) to the lid 28.
It should be appreciated to ~hose skilled in the art that the benefits attributable to the batch layer 54 in the cooled metal lid 28 are equally attributable to a : ~ :
lid of any construction, for example, refractory blocks.
The layer 54 will help seal and insulate the lid, maintain lower heat loss within the vessel 10, provide protection against accelerated chemical and abrasive attack and keep the refractory surface at a lower temperature and thus increase its effective service life. In addition, the new structure may be used to protect exposed portions within this vessel 10 other than the lid 28. For example, it may be used to provide a protective layer on the inner surface 60 of lid support blocks 31. Furthermore, blocks 31 may be constructed in a manner similar to that of the lid 28 shown in Figure 1 i.e., fluid cooled, metal construction, so that the cooling rate of the blocks 31 may be controlled to vary the thickness of a built-up protective layer.
Figure 7 illustrates an alternate liquefartion vessel 110 similar to the type disclosed in ~.S Patent No.

133 12~2 4,668,272 to Newcamp et al. A steel drum 112 is suspended from a circular frame 114 by struts 116, which is mounted on a plurality of support rollers 118 and aligning rollers 120, for rotation about a generally vertical axis corresponding to the center line of the drum 112. An outlet 122 below the drum 112 includes a bushing 124 with an open center 126. Lid 128, which is the subject of this invention, is provided with a stationary support by way of a frame 130 which is mounted independently from and aboye the rotating drum 112 as shown in Figure 7. The lid 128 includes one or more openings 132 for inserting a high temperature burner 134 into the vessel 110.
Within the liquefaction vessel 110, a stable layer of unmelted batch 136 is maintained on the walls of the drum 112 and encircling the central cavity within which combustion and melting takes place. The heat from the burners causes a surface portion 138 of the batch to become liquefied and flow downwardly toward and through the bottom opening 126. The liquefied batch then flows out of the liquefaction vessel 110 and may be collected in a vessel 140 below the liquefaction vessel 110 ~or further processing as needed, for example as shown in U.S. Patent Number 4,381,934 to Kunkle et al. Exhaust gases escape either upwardly through an opening in the lid 128 and into an exhaust outlet 142 or downwardly through the bottom opening 126 at the bushing 124. ~ -During the melting process in the liquefactionvessel 110, various matarials become entrained in the hot ,, . ~ . . . . ,~, .. .. . .

` ~33~2 exhaust gas stream. For example, in a typical soda-lime-silica glass batch, these entrained materials may include vapors such as, but not limited to, sodium oxide and particulates such as, but not limited to, sodium sulfate or sodium carbonate, all of which are highly corrosive. The vapors and particulates combine with the hot exhaust gas to form a corrosive and abrasive gas stream that will corrode inner surface 144 of the lid 128 that is exposed to the gas. In particular, the inner surface 144 is subjected to oxidation and sulfidation in the high temperature environment. The high temperature within the liquefaction vessel 110, which typically is in the range between approximately 2400F to 2600F (1316C
to 1427~C) near the lid surface 144, accelerates this corrosion and wear. In addition, particulates entrained in the gas stream may further erode the surface 144. It has been observed that this mechanical and chemical attack may wear alumina/zirconia/silica refractory at a rate in excess of one quarter inch (O.64 cm) per 24 hour elapsed time period.
one method of reducing the wearing action of the exhaust gas on exposed portions of vessel 110, and in particular on lid 128, is to direct a high velocity gas from a gas jet between the exhaust gas and the exposed 25 portion as taught in U.S. Patent No. 4,675,041 to Tsai. -~
The high velocity gas minimizes contact between the exhaust gas and the exposed portions of the vessel so as to reduce wear due to corrosive degradation.

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The present disclosure permits another way to protect the exposed portions of the vessel from the circulating exhaust gas. Referring to Figures 8 through 10, the lid 128 is constructed from a plurality of lid 5 modules 146 each including a main base plate 148 and a high temperature, wear resistant overlayment 150 on the hot face 144 of the lid 128. The term "wear resistant" as used herein includes, but is not limited to, resistance to corrosion, abrasion, oxidation or any other surface depletion mechanism that will reduce the effective operating life of the lid 128. The overlayment 150 is preferably a plate or a weld overlay as will be discussed later. Although not limited in the present invention, in the preferred embodiment of the invention, the overlayment 150 is a chromium alloy stainless steel. The surface of a chromium alloy steel will oxidize leaving a chromium oxide layer that protects and seals the underlying steel against further oxidation and chemical attack. Chromium alloy steels are also abrasion resistant.
In the area of glass melting, ferritic stainless steel is preferred over austenitic stainless steel because the former has little or no nickel. If nickel from the lid 128 gets into the melted glass, it will form a nickel sulfide stone defect in the final glass ribbon. In the following discussion reference to the properties of chromium steel will be to ferritic steel but it should~be appreciated that similar problems may occur with austenitic stainless steels.

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` ~3312~2 ~ 23 -Generally, the higher the chromium content in the steel the greater its oxidation and corrosive resistance, but the use of chromium steels present additional problems. For example, chromium steels containing more than about 15% chromium by weight and exposed to sustained temperatures in the range of about 750F to 1050F (399DC
to S66C) may increase in hardness with a corresponding decrease in ductility. This embrittlement ~ncreases with increasing chromium and time at temperature. As a res~lt, even though a lid surface 144 exposed directly to an intense heat of greater than 1000F (538C) is constructed of chromium steel with a high content of chromium, if the temperature gradient through the overlay thickness is such that portions of the overlay are maintained within a critical predetermined temperature range, the lid 128 may develop internal cracking.
~ o prolong the useful life of the lid 128, the temperature of the lid 128, and more particularly, the overlayment 150, is controlled to avoid embrittlement. In the particular embodiment of the invention illustrated in Figures 8 through 10, each module 146 of the lid 128 is cooled by circulating coolant, preferably water, through a series of ducts 152 formed, for example, by pipe members divided along their longitudinal axis and welded to the cold face 154 of the base plate 148. This cooling arrangement is easily fabricated and avoids the need ~o-form base plate 148 with integral ducts. Individual inlets 156 and outlets 15~ allow the amount of coolant " . .: :-, .: ` . . ' . ' ~ ' ; ;, ''' ~ . : -circulating through the ducts 152 to be varied so as to provide individual temperature control of each module 146 of the lid 128, if required. In addition, the inlets 156 and outlets 158 allow a single module 146 to be removed from the lid 128, as will be discussed later, without affecting the coolant circulation to the other modules 146.
The use~ul life of the lid 128 may be prolonged further by providing a protective cover for overlayment 150. In the preferred embodiment of the invention, the lid 128 is cooled to a temperature such that material circulated by the hot exhaust gas within the vessel 110 will begin to adhere to it in a manner similar to that taught in U.S. Patent 4,789,390 to Kunkle et al issued 6 December 1988.
In the initial stages of the vessel 110 heatup, the exhaust gas with the vessel 110 may include, but is not limited to, entrained airborne particulates ~uch as sand grains, dolomite and limestone, molten sodium carbonate, and molten glass cullet particles. At a sufficiently low hot face 144 temperature, material such as molten glass cullet and sodium carbonate will condense and "freeze" on the hot face 144 with additional glass cullet and sodium carbonate, as well as other solid particulate materials and condensed vapors, building up thereon. This built-up layer 160 has a coefficient of thermal conductivity at least an order of magnitude lower than the metal lid r28 and therefore provides an insulating effect so that more heat stays within the vessel 110 and less is removed 133~2 through the lid 128. As the temperature within the vessel llO increases due to less heat loss, additional particulates within the exhaust gas stream begin to soften and also stick to the previously deposited batch layer 160 further increas~ng its insulating qualities. This in turn further reduces the heat loss through the lid 128 and increases the temperature within the vessel 110. In addition, unsoftened particulates are captured by the heat softened layer, further adding to its thickness and insulative properties. At a sufficiently high temperature within the vessel 110, the deposited material in layer 160 will start to melt at the surface exposed to the interior of the vessel 110 and drip back into the vessel llO, thus limiting the thickness of the batch layer 160 build-up and maintaining it at a generally constant layer thickness, with a correspondingly reduced heat loss. At this steady ~-state condition, the final batch layer 160 thickness will directly relate to khe types of material being heated and the interior temperature within the vessel llO.
The batch layer 160 provides several interrelated functions. The layer 160 protects the surface against abrasive particles circulating within the vessel. It is contemplated that some of the particulates will get "stucki' to the layer and become part of the layer 160 itself. The layer 160 further functions as an insulator that both reduces the heat loss within the heating vessel 110 through the lid 128, and lowers the temperature of the hot face 144, thus reducing the effects of heat ~-... ~ .. . . .... .... ..

., " ~. , . :~ . ., .. :
. . ~ . ~ , , ~331282 degradation. The layer 160 also seals the face 144 and protects it from chemical attack. Specifically, the layer 160 provides a barrier between the face 144 of the lid 128 and oxygen, moisture, and corrosive vaporous gases that circulate within the vessel 110, all of which will attack and corrode the lid hot face 144. Since chemical reactions are generally accelerated at high temperatures, the reduced temperature of the hot face 144 of the lid 128, due to the insulating layer 160, reduces the rate of any chemical attack at the ~ace 144 by corrosive materials and thus prolongs the lid life. However, it should be noted that the batch layer 160 itself is corrosive due to, for example, the sulfur content in the layer 160 which results in sulfidation attack, so that the hot face 144 of the lid 128 must still be resistant to chemical attack.
As the layer 160 increases in thickness, it is -~ -possible that a portion of the layer 160 may fall off exposing an area of the hot face 144 of the lid 128. As a result, there may be a temporary loss of insulating effect requiring sudden change in heating and cooling demands.
This may lead to difficulty in controlling internal vessel temperature and the amount of coolant required for the lid 128. If desired, the hot face 144 of the lid may include anchoring devices such as, but not limited to, foraminous members 162, such as expanded metal, perforated plates, or screening secured to face 144 of the lid 128 to hold the layer 160, as shown in Figures 7, 9 and 10. The foraminous members 162 must be heat resistant and :`~

adequately attached to the lid 128 for sufficient cooling and to help support the layer 160 as it builds on the hot ~ace 144.
In the particular embodiment of the invention illustrated in Figures 8 through 10, the lid 128 is fabricated from a 1 1/2 inch (3.~I cm~ thick base plate 48 of low carbon steel, for example AISI 1010 steel, a 1/4 inch (0.64 cm) thick intermediate plate 164 of chrome steel having approximately lo to 16 percent chrvmium lo content by weight and a 1/4 inch to 3/8 inch (0.64 to 0.95 cm) sxposed inner plate 166 of chrome steel with approximately 16 to 27 percent chromium content by weightO The preferred coolant is water which is circulated through the ducts 152 to maintain the lid surface 144 at temperatures between 900F to 1200F ~482C
to 649C). If required, chromium steel side plates 168 may be added to protect the side faces of the base plate ;
148, as illustrated in Figures 8 through 10. No. 16 expanded metal mesh fabricated from 410 stainless steel is tack welded at approximately 2 to 3 inch centers (5.08 cm to 7.62 cm) to plate 166 of the lid 128.
As discussed above, if the plate 166 is too thick, a portion of the plate may be cooled by a combination of ::
the water cooling and/or the layer 160 build-up, to a temperature range within which cracking may occur due to the temperature gradient through the plate thickness. ~For example, if the plate 166 is constructed from chromium steel that is 125 percent by weight chromium and the plate - 28 - ~ 3 3 ~ 2 ~ 2 166 is cooled so that the temperature gradient from the surface 144 through the plate 166 results in a portion of the plate thickness being maintained at a temperature within its embrittlement range, there is a possibility that internal cracking may occur in the inner plate 166.
By including an intermediate plate 164 of chromium steel that has a lower chromium content than the e.~osed lnner plate 166, and establishing the thicknesses of plates 164 and 166 so th~t under a predetermined set of operating .
parameters, the temperature gradient through the overlayment l5o is such that the entire thickness of plat~
166 is maintained above the embrittlement temp rature -range of 25% chromium content chromium steel, the plate 166 will not crack due to embrittlement. The lower chromium content steel can be maintained within the temperature range of the temperature gradient that will cause e~brittlement of the 25% chromium content steel because, due to its lower chromium content, the embrittlement temperature range is lower. As a result, the intermediate plate 164 will not e~perience the same adverse affects within the embrittlement temperature range of the 25% chromium content steel so that the risk o~
embrittlement in either plate of the overlayment 150 is reduced.
It should be appreciated that a single plate of chromium steel having an embrittlement temperature range outside the temperature range of the temperature gradient through the overlayment 150 may be used so as to eliminate - ~: - - .: , : i . .

1331~82 cracking due to embrittlement. ~ low chromium content chromium steel may have an embrittlement temperature range below the tamperature gradient temperature range so that cracking due to embrittlement will not occur, but low chromium content chrome steel is less wear resistant than higher chromium content steels. On the other hand, a high chromium content chrome steel with an embri~.tlement range above the temperature gradient temperature range, may provide adeguate wear resis~ance but is more expensive than lower chromium content chrome steel.
As an alternative, the overlayment 150 on the hot face 144 may be constructed from multiple layers of the same chromium content chrome steel. With this arrangement, using high chromium content steel, the steel 15 plates positioned between the main plate 148 and exposed ;
outermost chromium steel plate may crack without the crack propagating through the overlayment 150 to the hot face 144 of lid 128. If lower chromium content steel is used, the exposed outermost plate may crack but the interior plates will not, so that the main plate 148 is protected.
The plates 164 and 166 may be secured to the main plate 148 in a number of ways well known in the art, such as conventional welding, explosion welding and roll bonding. It should be noted that the integrity of a conventionally welded system is limited by the defects that are inherent in the welding process, for example-microcracking, voids, etc. In addition, conventional weldin~ may not provide the degree of heat transfer - 30 - ~ 3 3 ~ 2 ~2 between metal plates as is required in a high temperature operation. For the high temperature applications, explosion welding is the preferred method since it provides the continuous, intimate contact between plates that is necessary for good thermal conductivity through the lid. If explosion welding is used for fabrication, care must be taken to be sure that the impact strength of the plate materials is high enough to withstand the explosion welding techniques.
It should be appreciated that although in the preferred embodiment of this invention, the overlayment 150 is chromium steel, other alloys may be used, e.g., Alpha IV* which is an aluminum and chromium alloy available from Allegheny Ludlum Corp., Pennsylvania, and Stellite 6* which is a cobalt and chromium alloy available from Cabot Stellite Division, Indiana.
As an alternative, the overlayment 150 may be a weld overlay, i.e., a series of weld beads deposited side by side covering the entire hot face 144 of the lid 128.
In the particular embodiment of the invention illustrated in Figures 11 and 12, chromium steel weld beads 170 are applied to the base plate 148 by any of a number of well known welding techniques, such as submerged arc welding, which is preferred, and metal insert gas weldings. The weld area 172 i9 preferably kept small to reduce distortion of the base plate 148 which may warp or bow-if long weld beads 170 are used. After one layer 174 of weld overlay is applied, subsequent weld overlay layers 176 may *Trade-mark -- 31 _ 1 3 3 ~ 2 ~ 2 be added, with the additional layers having a di~ferent chromium content if required, to avoid embrittlament as already discussed.
A weld overlay provides the intimate bond with the base plate 148 that is required for good thermal conductivity between base plate 148 and layer 174, but welding presents additional concerns that must be addressed~ When a chromium alloy bead is applied to base plate 148, the two metals combine and the chromium content in the resulting bead is diluted, i.e., the chromium content will be approximately the average chromium content of the base material and the overlay material. For example, if the base material has no chromium and the weld overlay material is 20% chromium by weight, the resultant bead will be approximately 10% chromium i.e., (0% chromium in base plate + 20~ chromium in overlay material)/2. lt should be noted that successive passes of chromium overlayment material to build up the overlayment 150 thickness will result in less dilution since the underlying material will contain ohromium. Continuing with the previous example, if a second layer of the same weld overlay material is added over the first layer, the resulting chromium content in the second layer will be approximately 15%, i.e., (10~ in fir~t layer + 20~ in second layer)/2. It is obvious that the greater the number of weld passes, the less the chromium content -reduction and thus the higher the resulting chromium content.
In addition, the type of base plate 148 material may influence the effectiveness of the weld overlay. It has been found that when the carbon content o~ the base plate 148 is too high, for example, as in cast iron, the chromium in the overlay material combines with the carbon to form chromium carbide. This co~bination reduces or eliminates the chromium available to form the chromium oxide protective lay~r as discussed earlier. To a~oid this situation, low carbon and/or low carbon chromium steel base plate materials should be used. As an alternative, if the base plate carbon content is too high, a weld overlay layer of low carbon content material, such as pure iron, may be positioned between the base plate 148 and the chromium alloy steel weld overlay to act as a buffer and reduce chromium depletion from the weld overlay.
In the particular embodiment shown in Figures 11 and 12, 1/8 inch (0.32 cm) thick beads 170 of 25% chromium content alloy steel are applied in approximately 6 inch by 6 inch (15.24 cm by 15.24 cm) weld areas 172 to cover a 2 1/2 inch (6.35 cm) thick low carbon steel base plate 148.
Two 1/8 inch (0.32 cm~ thick layers of weld overlay 178 protects the sides of the base plate 148. Stainless steel expanded metal 180 may be used to cover the hot face 144 and support the batch layer 182 which may be formed as discussed earlier.

_ 33 _ ~ 3 3 1 2 g 2 The thickness of the base plate 148 and overla~ment 150 and the cooling arrangement in any embodiment of the present invention are all interrelated and depend on the operating conditions of the vessel 1107 The temperature at the hot face 144 of the lid 128 depends on the temperature within the vessel 110 and the amount of cooling in the lid 128. Cooling, in turn, depends on the thickness of the base plate 148 and overlayment 150 and their respective coefficients of the thermal conductivity and the spa~ing of the cooling ducts 152 on the cold face 154 of base plate 14B, as well as the desired temperature ; :~
at hot ~ace 144. Also, as discussed earlier, embrittlement of the chromium overlayment 150 will determine layer thickness.
In the preferred embodiment of this invention, each individual module 146 is supported such that it may be removed without affecting the operation of the remaining modules 146 in a manner similar to that disclosed in U.S.
: Patent 4,704,155 to Matesa et al. issued 3 November 1987.
In the particular embodiment of the invention illustrated in Figures 7 and 9, modules 146 are supported from beam 184 of support frame 130 via tie rod 186 and hanger 188.
Clevis member I90 of tie rod 186 is pinned to hanger 18 while the upper end of rod 186 is removably secured to beam 184.
: Each module 146 is preferably interconnected in- any convenient fashion with adjacent modules to form a unitary lid structure. In the particular embodiment of the _ 34 _ 1331282 invention illustrated in Figure 10, bolt 192 extends through opposing ends of tie plate 194 and into bolt hole 196 of main plate 148. Collars 198 maintain tie plate 194 in spaced relation from main plate 148.
Positioning plates 200, similar in construction to hangar 188, may be provided ~or handling the module 146 as it is moved into and out of position in the lid 128 by a lifting mechanism, e.g., overhead hoist ~not shown). The hoist may lower an assembly (not shown) to connect to positioning plates 100. The hoist cable is then tensioned so as to support the module 146 as the tie rod 186 and tie plates 194 are disconnected and the inlet 156 and outlet 158 are uncoupled from the coolant supply ~not shown).
The hoist then lifts the lid module 146 out from the lid 128, transfers it to an unloading site and returns to the opening in the lid 128 with a new lid module 146. As an alternative, the modules 146 may be lifted directly by the tie rod 186.
It should be appreciated that although the embodiments of the invention disclosed in Figure 7 through 12 illustrate a flat lid with rectangular removable modules, other lid and/or module configurations may be used. For example, the lid 12~ may be domed and/or the modules 146 may be wedge shaped as taught in U.S. Patent 25 4,704,1~5.
The modular construction of lid 128 allows the-use of modules with different thickness of overlayment 150 at different locations. For example, the overlayment 150 for :~ ' " ? .. `: . . ~
r ~ ~

_ 35 _ 133128~
modules 146 at potential problem areas, such as in the vicinity of a material loading chute (not shown) or an exhaust outlet 142, may be thicker than other lid portions.
In addition, the lid design described may be combined with other lid or roof configurations wherein only selected portions o~ the roof require continual monitoring and replacement due to temperature and/or corrosive and/or abrasive conditions within the heating vessel. Fox example, a roof may be a continuous, one piece structure over a majority of the vessel with replaceable modules 146 at potential problem areas.
~ he forms of this invention shown and described in this disclosure represent illustrative embodiments and it is understood that various changes may be made without departing from the scope of the invention.

Claims (14)

1. In a method of liquefying pulverulent batch material including the steps of depositing said material into an enclosed heating vessel along a sloped surface substantially encircling a cavity in said vessel, raising the temperature within said vessel with a high velocity combustion type heating means to liquefy said material wherein said heating means is positioned to direct heat along said sloped surface and exhaust gas from said heating means circulates within said vessel, and removing said exhaust gas from said heating vessel, wherein said circulating exhaust gas includes entrained particulate and molten material resulting from liquefying said batch material having corrosive properties which degrades selected exposed lid surface portions of said vessel as said exhaust gas circulates within said vessel prior to exiting said vessel, the improvement comprising:
cooling said exposed surface to a temperature such that said entrained, circulating particulate and molten materials contacting said cooled surface adhere to said surface and form a protective layer on said surface; and controlling the cooling of said surface during said cooling step so as to adhere additional materials entrained in said circulating exhaust gas to said materials previously adhered to said surface and adjust the thickness of said layer.

2. The method as in claim 1 wherein said protective layer thermally insulates said exposed lid surface and further including the step of increasing the thickness of said layer until the temperature with said vessel is sufficient to melt newly deposited entrained material on said layer so as to maintain relatively constant layer thickness on said surface and a relatively constant heating temperature within said vessel.

3. The method as in claim 2 further including the step of varying the amount of heat in said vessel so as to vary the thickness of said layer.

4. The method as in claim 1 further including the step of coating said lid surface with a refractory cement prior to said heating step.

5. The method as in claim 1 further including the step of providing anchors on said exposed lid surface to help secure said layer to said exposed lid surface.

6. The method as in claim 1 further including the step of securing heat resistant foraminous members to exposed lid surface to help secure said layer to said exposed lid surface.

7. The method as in claim 2 wherein said material is glass batch.

8. In an apparatus for melting material of the type having a heating vessel with a lid, means to deposit said material along a sloped surface substantially encircling a cavity in said vessel, a high velocity combustion type heating means to direct heat along said sloped surface and melt said material wherein exhaust gas from said heating means circulates within said vessel, and means to remove said exhaust gas from said vessel wherein said circulating exhaust gas includes entrained particulate and molten materials resulting from the melting of said material having corrosive properties which degrades selected exposed surface portions of said lid as said exhaust gas circulates within said vessel prior to exiting said vessel, the improvement comprising:
means to cool said exposed lid surface portions such that entrained circulating particulate and molten materials adhere to said surface forming a protective layer; and means to control said cooling means to adjust the thickness of said protective layer.

9. The apparatus as in claim 8 further including means to increase the surface area of said exposed surface.

10. The apparatus in claim 8 further including means to anchor said layer to said exposed surface.

11. The apparatus as in claim 8 wherein said exposed surface includes grooved surface portions.

12. The apparatus as in claim 8 further including foraminous members secured to said exposed surface of said lid.

13. The apparatus as in claim 12 wherein said foraminous expanded metal.

14. The apparatus as in claim 8 wherein said batch material is glass batch material.