CN112830661A - Large-length-width-ratio high-electric-load type mixed melting kiln and melting process - Google Patents
Large-length-width-ratio high-electric-load type mixed melting kiln and melting process Download PDFInfo
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- CN112830661A CN112830661A CN202110057418.6A CN202110057418A CN112830661A CN 112830661 A CN112830661 A CN 112830661A CN 202110057418 A CN202110057418 A CN 202110057418A CN 112830661 A CN112830661 A CN 112830661A
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- C—CHEMISTRY; METALLURGY
- C03—GLASS; MINERAL OR SLAG WOOL
- C03B—MANUFACTURE, SHAPING, OR SUPPLEMENTARY PROCESSES
- C03B5/00—Melting in furnaces; Furnaces so far as specially adapted for glass manufacture
- C03B5/02—Melting in furnaces; Furnaces so far as specially adapted for glass manufacture in electric furnaces, e.g. by dielectric heating
- C03B5/027—Melting in furnaces; Furnaces so far as specially adapted for glass manufacture in electric furnaces, e.g. by dielectric heating by passing an electric current between electrodes immersed in the glass bath, i.e. by direct resistance heating
- C03B5/03—Tank furnaces
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- C—CHEMISTRY; METALLURGY
- C03—GLASS; MINERAL OR SLAG WOOL
- C03B—MANUFACTURE, SHAPING, OR SUPPLEMENTARY PROCESSES
- C03B3/00—Charging the melting furnaces
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- C—CHEMISTRY; METALLURGY
- C03—GLASS; MINERAL OR SLAG WOOL
- C03B—MANUFACTURE, SHAPING, OR SUPPLEMENTARY PROCESSES
- C03B5/00—Melting in furnaces; Furnaces so far as specially adapted for glass manufacture
- C03B5/16—Special features of the melting process; Auxiliary means specially adapted for glass-melting furnaces
- C03B5/18—Stirring devices; Homogenisation
- C03B5/183—Stirring devices; Homogenisation using thermal means, e.g. for creating convection currents
- C03B5/185—Electric means
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Abstract
The invention discloses a large length-width ratio high-power load type mixed melting kiln which comprises electrode bricks, throat flow holes, a feed port, a feed device, side pool wall bricks, rear pool wall bricks, a burner port, a breast wall and front pool wall bricks; the front tank wall brick, the rear tank wall brick and the two side tank wall bricks surround to form a kiln tank, and a plurality of counter electrode bricks are arranged on the two side tank wall bricks; a breast wall is arranged above the kiln pool, a burning gun port is arranged on the breast wall and used for fixing a burning gun, and the electrode brick and the burning gun are used for mixing and heating the inside of the kiln pool; a feed port is arranged on the front pool wall brick, a feed device is arranged on the feed port, and a throat flow liquid hole is arranged at the bottom of the rear pool wall brick; the inside of the kiln pool is sequentially provided with a pre-melting zone, a clarifying zone and a homogenizing zone from a feeding port to a throat, wherein the length of the clarifying zone is greater than that of the homogenizing zone, and the length of the homogenizing zone is greater than that of the pre-melting zone. The melting, clarifying and homogenizing processes of the glass batch with large batch size are met, and a melting process with low defect and high quality is provided.
Description
Technical Field
The invention belongs to the technical field of glass substrate manufacturing, and particularly belongs to a large length-width ratio high-power load type mixed melting kiln and a melting process.
Background
Glass products have been widely used in the display field, from the traditional color picture tube industry to the current flat panel display industry, glass has been used as a key component to play a key role in a display device, actually is a frame and a carrier of the whole device, and is also an optical element, and as an upper substrate and a lower substrate of the flat panel display device, the glass substrates need a fine microscopic semiconductor process processing procedure, and the glass batch materials are melted, clarified and homogenized in a kiln in the manufacturing process of the glass substrates, so that qualified and homogeneous glass liquid is provided for the next procedure. The glass liquid melted by the kiln is alkali-free high-alumina borosilicate glass, and the glass product is mainly a glass substrate for flat panel display.
The production and manufacturing of high-generation, wide-width and ultra-fine glass substrates inevitably needs high-tonnage eduction and process quality to meet the continuous production requirements of the glass substrates, and the existing kiln structure and heating process can not produce the high-generation, wide-width and ultra-fine glass substrates.
Disclosure of Invention
In order to solve the problems in the prior art, the invention provides a large-length-width-ratio high-power load type mixed melting kiln and a melting process, which meet the melting, clarifying and homogenizing processes of glass batch with large batch size, and provide a low-defect and high-quality melting process for the production of high-generation glass substrates.
In order to achieve the purpose, the invention provides the following technical scheme:
a large length-width ratio high-electric load type mixed melting kiln comprises electrode bricks, throat holes, a feeding port, a feeding device, side pool wall bricks, rear pool wall bricks, a burner port, a breast wall and front pool wall bricks;
the front tank wall brick, the rear tank wall brick and the two side tank wall bricks surround to form a kiln tank, and a plurality of pairs of electrode bricks are arranged on the two side tank wall bricks; a breast wall is arranged above the kiln pool, a burning gun port is arranged on the breast wall and used for fixing a burning gun, and the electrode brick and the burning gun are used for mixing and heating the inside of the kiln pool;
a feeding port is formed in the front pool wall brick, a feeding device is arranged on the feeding port, and a throat flow liquid hole is formed in the bottom of the rear pool wall brick; the furnace tank is internally provided with a premelting zone, a clarifying zone and a homogenizing zone in sequence from a feeding port to a throat, wherein the length of the clarifying zone is greater than that of the homogenizing zone, and the length of the homogenizing zone is greater than that of the premelting zone.
Preferably, the bottom of the kiln pool is provided with a pool bottom brick, and the pool bottom brick is provided with a thermocouple hole.
Preferably, the height of the glass liquid surface line in the kiln pool is not less than 960 mm.
Preferably, the heating heat ratio of the electrode brick to the combustion gun is 30-36: 64-70.
Preferably, the length ratio of the premelting zone to the clarifying zone to the homogenizing zone is 20-24%: 39-43%: 32-36 percent.
Preferably, the length-width ratio of a melting furnace of the mixing kiln is 3.28-3.48, the width of the mixing kiln is 2105-2116 mm, and the melting rate of the mixing kiln is not less than 1.32T/D.m2。
Preferably, the length range of the pre-melting zone is 1640-1650 mm; the length range of the clarification zone is 3140-3145 mm; the length range of the homogenizing zone is 2550-2555 mm.
A glass furnace melting process comprises the following steps of adding glass batch materials into a mixing melting furnace through a feeding device on a feeding port, heating the glass batch materials in a pre-melting area to form glass liquid with a mixed flow field, enabling the glass liquid of the mixed flow to flow into a clarifying area from the pre-melting area, continuously heating the glass liquid of the mixed flow in the clarifying area to form the glass liquid with a laminar flow state, enabling the glass liquid of the laminar flow state to flow into a homogenizing area from the clarifying area, continuously heating the glass liquid of the laminar flow state in the homogenizing area to form the glass liquid with a laminar flow and circular flow mixed state, and enabling the glass liquid of the laminar flow and circular flow mixed state to flow into the next procedure through a throat pipe flow liquid hole.
Preferably, the heat transfer efficiency of the mixing and melting kiln is 25-35%.
Preferably, the heating time of the molten glass in the kiln is not less than 45.43 h.
Compared with the prior art, the invention has the following beneficial technical effects:
the invention relates to a high-length-width-ratio high-electric-load type mixed melting kiln, which is characterized in that an electrode brick and a burning gun are adopted to mix and heat glass liquid in a kiln pool, a pre-melting area, a clarifying area and a homogenizing area are formed in the kiln pool, glass raw materials are melted in the pre-melting area and are converted into a glass phase to form the glass liquid, the glass liquid passes through the clarifying area to clarify bubbles in the glass liquid, and then passes through the homogenizing area to homogenize the glass liquid after bubble discharge. The melting, clarifying and homogenizing processes of the glass batch with large batch size are met, and a low-defect and high-quality melting process is provided for the production of high-generation glass substrates.
Furthermore, the length-width ratio of the melting furnace of the mixing kiln is set to be 3.28-3.48, and the melting rate is not less than 1.32T/D.m2The large length-width ratio effectively ensures the reasonable layout of the premelting area, the clarifying area and the homogenizing area inside the kiln pool, and ensures the high-quality melting process.
Furthermore, the width of the mixing kiln is 2105-2116 mm, when the width of the melting kiln is 2105-2116 mm, the voltage and the current of the electrode are in the most stable state, and the requirements of the distribution position of hot spots of the melting kiln and the heating power of each functional area are met.
The invention relates to a melting process of a glass kiln, which comprises the steps of heating glass batch in a mixing melting kiln to sequentially form mixed flow glass liquid, laminar flow glass liquid and laminar flow and circular flow mixed state glass liquid, sequentially passing through a pre-melting zone, a clarifying zone and a homogenizing zone to remove impurities and bubbles in the glass liquid, improving the melting quality and melting efficiency of the glass, meeting the melting, clarifying and homogenizing processes of the glass batch with large feeding amount, and providing a low-defect and high-quality melting process for the production of high-generation glass substrates.
Furthermore, the residence time of the glass liquid in the kiln is not less than 45.43h, so that the bubble discharge and circulation time is provided for efficient clarification and effective homogenization, and the glass melting quality is improved.
Drawings
FIG. 1 is a side view of a large length-width ratio high-electric load type mixing and melting furnace structure according to an embodiment of the present invention;
FIG. 2 is a distribution diagram of the process function areas of the glass melt effective space of the large length-width ratio high-power load type mixing and melting furnace according to the embodiment of the invention;
FIG. 3 is a schematic top view of molten glass in different functional areas of a melting furnace according to an embodiment of the present invention;
FIG. 4 is a schematic side view of molten glass in different functional areas of a melting furnace according to an embodiment of the present invention;
in the drawings: 1 is an electrode brick; 2 is a pre-melting zone; 3 is a clarification zone; 4 is a homogenizing zone; 5 is a thermocouple hole; 6 is a throat flow liquid hole; 7 is a feeding port; 8 is a feeding device; 9 is a feeding area; 10 is a pool wall brick; 11 is a rear pool wall brick; 12 is a burner port; 13 is a breast wall; 14 is a front pool wall brick; 15 is liquid surface line.
Detailed Description
The present invention will now be described in further detail with reference to specific examples, which are intended to be illustrative, but not limiting, of the invention.
The invention provides a large length-width ratio high-power load type mixed melting kiln and a melting process, wherein an electric melting heating system and a gas heating system are arranged in the large length-width ratio high-power load type mixed melting kiln, the electric melting heating system comprises a plurality of pairs of tin oxide electrodes, and the gas heating system comprises a plurality of pairs of fuel guns; according to the principle of energy conservation of a melting furnace heating system, the gas heat and the electric melting heat of the mixed melting furnace are more than the heat required by glass melting and the heat taken away by the smoke of the melting furnace, the whole melting furnace wall body heat dissipation and the furnace arch heat dissipation; the heat efficiency of the large length-width ratio high-power load type mixed melting kiln is 25% -35%, the precise control of the temperature of the melting kiln is realized through the characteristics of more electricity and less gas, and the distribution of the gas-electricity ratio is calculated by combining the energy conservation and the heat consumption.
Examples
As shown in figure 1, the high-length-width-ratio high-electric-load type mixing melting kiln comprises electrode bricks 1, a throat flow liquid hole 6, a feeding port 7, a feeding device 8, side pool wall bricks 10, rear pool wall bricks 11, a fuel gun port 12, a breast wall 13 and front pool wall bricks 14;
the front tank wall brick 14, the rear tank wall brick 11 and the two side tank wall bricks 10 are encircled to form a kiln tank, and a plurality of pairs of electrode bricks 1 are arranged on the two side tank wall bricks 10; the bottom of the kiln pool is provided with a pool bottom brick, and the pool bottom brick is provided with a thermocouple hole 5. A breast wall 13 is arranged above the kiln pool, a burning gun port 12 is arranged on the breast wall 13 and used for fixing a burning gun, the flame nozzle direction of the burning gun points to the inside of the kiln pool, and the burning gun port 12 is higher than a liquid level line 15 in the kiln pool; the electrode brick 1 and the burning gun are used for mixing and heating the interior of the kiln pool.
As shown in fig. 2, a feeding port 7 is arranged on the front pool wall brick 14, a feeding device 8 is arranged on the feeding port 7, and a throat 6 is arranged at the bottom of the rear pool wall brick 11; the inside of the kiln pool is sequentially provided with a premelting area 2, a clarifying area 3 and a homogenizing area 4 from a feeding port 7 to a throat 6, wherein the length of the clarifying area 3 is greater than that of the homogenizing area 4, and the length of the homogenizing area 4 is greater than that of the premelting area 2.
The premelting zone 2, the clarifying zone 3 and the homogenizing zone 4 are in fluid states after the glass batch is converted into molten glass; the pre-melting zone 22 converts the batch materials into a glass phase to form molten glass within the temperature range of 1580-1610 ℃, and the clarifying zone 3 clarifies bubbles in the molten glass within the temperature range of 1620-1650 ℃; the homogenizing zone 4 is used for homogenizing the glass liquid after bubble discharge in the temperature range of 1620-1630 ℃ to remove the segregation problem of the components.
The invention relates to a melting process of a glass kiln, which comprises the following processes of adding glass batch materials into a mixing melting kiln through a feeding device 8 on a feeding port 7, stacking the glass batch materials in a feeding area 9, heating the glass batch materials in a pre-melting area 2 to form glass liquid with a mixed flow field, enabling the glass liquid of the mixed flow to flow into a clarifying area 3 from the pre-melting area 2, continuously heating the glass liquid of the mixed flow in the clarifying area 3 to form the glass liquid with a laminar flow field, enabling the glass liquid with the laminar flow state to flow into a homogenizing area 4 from the clarifying area 3, continuously heating the glass liquid with the laminar flow state in the homogenizing area 4 to form the glass liquid with a laminar flow and circular flow mixed state, and enabling the glass liquid with the laminar flow and circular flow mixed state to flow into the next process through a throat pipe throat 6.
According to the calculation formula of the electrode resistivity
And
calculating the distance between electrode bricks 1 of the electrode electric melting heating system, wherein when the distance between the electrode bricks 1 is 2105-2116 mm, the voltage and the current of the electrode are in the most stable state, and the requirements of the distribution position of hot spots of a melting furnace and the heating power of each functional area are met;
according to the Stokes calculation formula of the clear bubble removal of the molten glass in the embodiment of the invention
And the height of the liquid level of the melting furnace is not less than 960mm, so that the length of the clarified bubble discharge area can be calculated to be about 3140-3145 mm; calculating the feeding amount of 920kg/h according to GFM simulation software, wherein the length of the pre-melting zone 2 is about 1640-1650 mm; the length range of the clarification zone 3 is 3140-3145 mm; the length of the homogenizing zone 4 is 2550-2555 mm. Therefore, the length-width ratio of the mixing melting kiln is designed to be between 3.28 and 3.48, and the melting rate is not less than 1.32T/D.m2(ii) a The length ratio of the premelting zone 2 to the clarifying zone 3 to the homogenizing zone 4 is 20-24%: 39-43%: 32-36 percent. The large length-width ratio not only effectively ensures the reasonable layout of the premelting area, the clarifying area and the homogenizing area, but also meets the hot spot distribution position of the melting furnace and the heating power requirements of the electrodes of all functional areas; and the residence time of the molten glass in the kiln is not less than 45.43h, so that the bubble discharge and circulation time is provided for efficient clarification and effective homogenization.
The invention relates to a large length-width ratio high-electric load type mixed melting kiln and a melting process, and is shown in figure 1 as a side view of an M8 type kiln, wherein the side part of the kiln comprises a plurality of counter electrodes and a plurality of counter guns which are respectively an electric melting heating system and a gas heating system of the mixed melting kiln. According to the principle of energy conservation of a kiln system, the gas heat and the electric melting heat of the mixed melting kiln are more than the heat required by glass melting, the heat taken away by the smoke of the melting kiln, the heat dissipation of the whole melting kiln wall body and the heat dissipation of a kiln crown; the thermal efficiency of the mixed melting kiln is controlled to be 25% -35% through heat calculation, the heating heat ratio of the electrode brick 1 to the combustion gun is 30-36: 64-70, the precise control of the temperature of the melting kiln is realized through the characteristics of electricity utilization and less gas consumption, and the gas-electricity ratio is preferably distributed as G: and E is 35: 65.
In FIG. 2, the formula is calculated from the electrode resistivity
And
and calculating the electrode spacing and the width of the melting furnace, determining parameters such as electrode sectional area, electrode voltage, electrode current, electrode volume resistivity and the like, and meeting the requirements of the distribution position of hot spots of the melting furnace and the heating power of each functional area when the electrode spacing/the width of the melting furnace is determined by calculation as shown in table 1.
FIG. 2 shows a formula for Stokes calculation in accordance with the clarification and bubble removal of molten glass
And the height of the liquid level of the glass in the melting furnace is not less than 960mm, and the length of the clarified bubble discharge area can be calculated to be about 3140-3145 mm; calculating the feeding amount of 920kg/h according to GFM simulation software, wherein the length of a pre-melting zone of the melting furnace is about 1640-1650 mm; the length of the homogenizing area of the melting furnace is 2550-2555 mm. Therefore, the length-width ratio of the mixing melting kiln is designed to be between 3.28 and 3.48, and the melting rate is not less than 1.32T/D.m2(ii) a The large length-width ratio not only effectively ensures the reasonable layout of the melting process of the mixed melting furnace in the pre-melting zone 2, the clarifying zone 3 and the homogenizing zone 4, but also meets the hot spot distribution position of the melting furnace and the heating power requirements of the electrodes of each functional zone; and the residence time of the glass batch in the kiln is not less than 45.43h, the glass batch is efficiently clarified, the bubble discharge and circulation time is provided for effective homogenization, it can be seen from figures 3 and 4 that after the glass batch enters the mixing melting kiln through the feed opening 7, the flow field of the glass batch in the pre-melting zone 2 is mainly mixed flow, the flow field of the glass batch in the clarification zone 3 is mainly in a laminar flow state, and the flow field of the glass batch in the homogenization zone 4 is mainly in a laminar flow and circulation mixed state.
Claims (10)
1. A large length-width ratio high-electric load type mixing melting kiln is characterized by comprising electrode bricks (1), a throat flow liquid hole (6), a feed port (7), a feed device (8), side pool wall bricks (10), rear pool wall bricks (11), a fuel gun port (12), a breast wall (13) and front pool wall bricks (14);
the front pool wall brick (14), the rear pool wall brick (11) and two side pool wall bricks (10) surround to form a kiln pool, and a plurality of pairs of electrode bricks (1) are arranged on the two side pool wall bricks (10); a breast wall (13) is arranged above the kiln pool, a burning gun port (12) is arranged on the breast wall (13) and used for fixing a burning gun, and the electrode brick (1) and the burning gun are used for mixing and heating the inside of the kiln pool;
a feeding port (7) is formed in the front pool wall brick (14), a feeding device (8) is arranged on the feeding port (7), and a throat liquid flow hole (6) is formed in the bottom of the rear pool wall brick (11); the furnace tank is internally provided with a premelting zone (2), a clarifying zone (3) and a homogenizing zone (4) in sequence from a feeding port (7) to a throat (6), wherein the length of the clarifying zone (3) is greater than that of the homogenizing zone (4), and the length of the homogenizing zone (4) is greater than that of the premelting zone (2).
2. The high-length-width-ratio high-power-load type mixing and melting kiln as claimed in claim 1, wherein a bottom brick is arranged at the bottom of the kiln pool, and a thermocouple hole (5) is arranged on the bottom brick.
3. A high length-width-ratio high-electric-load type mixing and melting kiln as claimed in claim 1, characterized in that the height of the glass melt line (15) in the kiln pool is not less than 960 mm.
4. The high-length-width-ratio high-power-load type mixing and melting kiln as claimed in claim 1, wherein the heating heat ratio of the electrode bricks (1) to the combustion guns is 30-36: 64-70.
5. The high-length-width-ratio high-power-load type mixing melting kiln as claimed in claim 1, wherein the length ratio of the pre-melting zone (2), the clarifying zone (3) and the homogenizing zone (4) is 20-24%: 39-43%: 32-36 percent.
6. The high-length-width-ratio high-power-load type mixing and melting kiln as claimed in claim 1, wherein the length-width ratio of the melting kiln of the mixing kiln is 3.28-3.48, the width of the mixing kiln is 2105-2116 mm, and the melting rate of the mixing kiln is not less than 1.32T/D.m2。
7. The high-length-width-ratio high-power-load type mixing and melting kiln as claimed in claim 1, characterized in that the length of the pre-melting zone (2) ranges from 1640 mm to 1650 mm; the length range of the clarification zone is 3140-3145 mm; the length range of the homogenizing zone (4) is 2550-2555 mm.
8. A melting process of a glass kiln is characterized by comprising the following steps of adding glass batch materials into a mixing melting kiln through a feeding device (8) on a feeding port (7), heating the glass batch materials in a pre-melting area (2) to form glass liquid with a mixed flow field, enabling the glass liquid with the mixed flow to flow into a clarifying area (3) from the pre-melting area (2), continuously heating the glass liquid with the mixed flow in the clarifying area (3) to form the glass liquid with a laminar flow field, enabling the glass liquid with the laminar flow state to flow into a homogenizing area (4) from the clarifying area (3), continuously heating the glass liquid with the laminar flow state in the homogenizing area (4) to form the glass liquid with the laminar flow field and a circular flow mixed state, and enabling the glass liquid with the laminar flow and the circular flow mixed state to flow into the next process through a throat pipe throat liquid hole (6).
9. The glass furnace melting process of claim 8, wherein the heat transfer efficiency of the melting furnace is 25% to 35%.
10. The glass kiln melting process of claim 8, wherein the molten glass is heated inside the kiln for a time not less than 45.43 hours.
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| CN113880399A (en) * | 2021-09-28 | 2022-01-04 | 彩虹显示器件股份有限公司 | High-electric-load kiln structure-based molten glass homogenizing circulation method and device |
| CN115385553A (en) * | 2022-07-28 | 2022-11-25 | 陕西彩虹工业智能科技有限公司 | Microcrystalline glass's smelting device |
| CN115466037A (en) * | 2022-09-02 | 2022-12-13 | 湖南旗滨微晶新材料有限公司 | Special glass preparation system and preparation method of special glass |
| EP4306489A1 (en) * | 2022-07-15 | 2024-01-17 | Horn Glass Industries AG | Glass melting tank for full electric operation |
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| EP4306489A1 (en) * | 2022-07-15 | 2024-01-17 | Horn Glass Industries AG | Glass melting tank for full electric operation |
| CN115385553A (en) * | 2022-07-28 | 2022-11-25 | 陕西彩虹工业智能科技有限公司 | Microcrystalline glass's smelting device |
| CN115466037A (en) * | 2022-09-02 | 2022-12-13 | 湖南旗滨微晶新材料有限公司 | Special glass preparation system and preparation method of special glass |
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