WO2023278232A1

WO2023278232A1 - Apparatus and methods for cooling walls of a glass melting vessel

Info

Publication number: WO2023278232A1
Application number: PCT/US2022/034644
Authority: WO
Inventors: Pierre LARONZE; Kevin Scott Riegel
Original assignee: Corning Incorporated
Priority date: 2021-07-01
Filing date: 2022-06-23
Publication date: 2023-01-05
Also published as: KR20240028504A; JP2024523653A; TW202317485A; CN117642366A

Abstract

A glass manufacturing apparatus including a melting vessel, the melting vessel provided with one or more cooling panels positioned against one or more walls of the melting vessel. Each cooling panel includes a passage therein through which a cooling fluid is flowed, the cooling fluid extracting heat from the melting vessel wall to reduce the temperature thereof, thereby reducing deterioration of the melting vessel wall and prolonging the life of the melting vessel.

Description

APPARATUS AND METHODS FOR COOLING WALLS OF A GLASS MELTING

VESSEL

CROSS REFERENCE TO RELATED APPLICATIONS [0001] This application claims the benefit of priority under 35 U.S.C. § 119 ofU.S. Provisional Application Serial No.: 63/217,519, filed on July 1, 2021, the content of which is relied upon and incorporated herein by reference in its entirety.

FIELD

[0002] The present disclosure relates generally to glass manufacturing apparatus and methods and, more particularly, to glass manufacturing apparatus and methods for cooling walls of a glass melting vessel to prolong the melting vessel life.

BACKGROUND

[0003] The need to maintain melting vessel operation over prolonged periods of time at increased molten glass flow rates has strained the refractory materials used in the construction of the melting vessel. Typical melting vessels are formed by tiers of refractory material (e.g., refractory bricks and/or blocks). Overtime, the molten glass contained in the melting vessel can erode the refractory material, owing for example to flow erosion, and the high temperature and the corrosive nature of the molten glass. Eventually, the refractory material wears through, the melting vessel fails, and a new melting vessel must be built. The rebuild construction can impair production for a significant, and costly, time. Accordingly, there is a desire to delay shutdown and rebuild for as long as possible by slowing deterioration of the melting vessel.

SUMMARY

[0004] The following presents a simplified summary of the disclosure to provide a basic understanding of some embodiments described in the detailed description. These and other features, aspects and advantages are better understood when the following detailed description is read with reference to the accompanying drawings.

[0005] A glass manufacturing apparatus is disclosed comprising a melting vessel comprising a refractory glass contact wall, a cooling panel configured to receive a cooling fluid through an inlet port and to expel the cooling fluid through an outlet port, and wherein the cooling panel is in contact with and urged against the refractory glass contact wall by a pressure bolt in contact with the cooling panel. [0006] The inlet port may be positioned in a bottom half of the cooling panel and the outlet port may be positioned in a top half of the cooling panel.

[0007] In some embodiments, the refractory glass contact wall comprises a side wall of the melting vessel

[0008] In various embodiments, the cooling panel comprises a serpentine passage extending therein between the inlet port and the outlet port.

[0009] In some embodiments, the cooling panel comprises a base portion and a cover portion, the serpentine passage machined into the base portion and the cover portion attached to the base portion, for example with one or more fasteners, although in further embodiments, the cover portion can be permanently affixed to the base portion, such as by welding. The base portion may be positioned in contact with the refractory glass contact wall.

[0010] In some embodiments, the base portion comprises a back surface including a recess formed therein. A conformable thermally conductive material may be positioned in the recess between the cooling panel and the refractory glass contact wall.

[0011] In some embodiments, the cooling panel comprises at least one thermocouple. [0012] In some embodiments, the melting vessel comprises a plurality of cooling panels in contact with and urged against the refractory glass contact wall. The plurality of cooling panels may be supplied with the cooling fluid through a single cooling fluid header. Each cooling panel may be supplied from the cooling fluid header through a coolant line, the coolant line of each cooling panel including an isolation valve.

[0013] In some embodiments, the cooling panel may be provided with at least one handle to aid with installation of the cooling panel.

[0014] The pressure bolt can be positioned between a bracing member and the cooling panel, the pressure bolt coupled to the bracing member. In some embodiments, a plurality of pressure bolts may be used to secure the coolingpanel to the melting vessel. [0015] In some embodiments, the glass manufacturing apparatus may further comprise a metal grating panel in contact with and urged againstthe refractory glass contact wall. For example, the metal grating panel may be positioned below the coolingpanel. [0016] In some embodiments, the metal grating panel may be supported at least in part by one or more refractory blocks positioned beneath the metal grating panel.

[0017] In some embodiments, the meltingvessel may comprise a secondmetal grating panel in contact with and urged against the refractory glass contact wall, the second metal grating panel positioned above the coolingpanel. [0018] Additional features of the embodiments disclosed herein will be set forth in the detailed description that follows, and in part will be clear to those skilled in the art from that description, including the claims and appended drawings. Both the foregoing general description and the following detailed description present embodiments intended to provide an overview or framework for understanding the nature and character of the embodiments. The accompanying drawings are included to provide further understanding and are incorporated into and constitute a part of this specification. The drawings illustrate various embodiments of the disclosure, and together with the description explain the principals and operations thereof.

BRIEF DESCRIPTION OF THE DRAWINGS

[0019] FIG. 1 is a schematic view of an exemplary glass manufacturing apparatus; [0020] FIG. 2 is a perspective view of an exemplary melting vessel;

[0021] FIG. 3 is a top view of an interior of an exemplary melting vessel;

[0022] FIG. 4 is a perspective view of an exemplary melting vessel disposed within a rigid exoskeleton;

[0023] FIG. 5 is a cross-sectional view of an exemplary lower refractory side wall of the melting vessel of FIG. 2;

[0024] FIG. 6 is an exploded cross-sectional view of an exemplary cooling panel accordingto embodiments disclosed herein as seen along line 5-5 of FIG. 6;

[0025] FIG. 7 is a top view of a base portion of the cooling panel of FIG. 5 showing a serpentine passage extending therein formed by a plurality of walls, e.g., baffles; [0026] FIG. 8 is a top view of a cover portion of the cooling panel of FIG, 5;

[0027] FIG. 9 is a side view of the cooling panel shown in FIG. 4 and positioned against the lower refractory side wall of the melting vessel; and

[0028] FIG. 10 schematically depicts a pressure bolt for coupling a melting vessel, or components thereof, to the rigid exoskeleton accordingto one or more embodiments shown and described herein.

DETAILED DESCRIPTION

[0029] Reference will now be made in detail to embodiments of the present disclosure, examples of which are illustrated in the accompanying drawings. Whenever possible, the same reference numerals will be used throughout the drawings to refer to the same or like parts. However, this disclosure can be embodied in many different forms and should not be construed as limited to the embodiments set forth herein.

[0030] As used herein, the term “about” means that amounts, sizes, formulations, parameters, and other quantities and characteristics are not and need not be exact, but may be approximate and/or larger or smaller, as desired, reflecting tolerances, conversion factors, rounding off, measurement error and the like, and other factors known to those of skill in the art.

[0031] Ranges can be expressed herein as from “about” one particular value, and/or to “about” another particular value. When such a range is expressed, another embodiment includes from the one particular value to the other particular value. Similarly, when values are expressed as approximations by use of the antecedent “about,” it will be understood that the particular value forms another embodiment. It will be further understood that the endpoints of each of the ranges are significant both in relation to the other endpoint, and independently of the other endpoint.

[0032] Directional terms as used herein - for example up, down, right, left, front, back, top, bottom - are made only with reference to the figures as drawn and are not intended to imply absolute orientation.

[0033] Unless otherwise expressly stated, it is in no way intended that any method set forth herein be construed as requiring that its steps be performed in a specific order, nor that with any apparatus, specific orientations be required. Accordingly, where a method claim does not actually recite an order to be followed by its steps, or that any apparatus claim does not actually recite an order or orientation to individual components, or it is not otherwise specifically stated in the claims or description that the steps are to be limited to a specific order, or that a specific order or orientation to components of an apparatus is not recited, it is in no way intended that an order or orientation be inferred in any respect. This holds for any possible non-express basis for interpretation, including matters of logic with respect to arrangement of steps, operational flow, order of components, or orientation of components, plain meaning derived from grammatical organization or punctuation, and the number or type of embodiments described in the specification.

[0034] As used herein, the singular forms "a," "an" and "the" include plural references unless the context clearly dictates otherwise. Thus, for example, reference to “a” component includes aspects having two or more such components, unless the context clearly indicates otherwise. [0035] The word “exemplary,” “example,” or various forms thereof are used herein to mean serving as an example, instance, or illustration. Any aspect or design described herein as “exemplary” or as an “example” should not be construed as preferred or advantageous over other aspects or designs. Furthermore, examples are provided solely for purposes of clarity and understanding and are not meant to limit or restrict the disclosed subjectmatterorrelevantportionsofthis disclosure in any manner. Amyiiad of additional or alternate examples of varying scope could have beenpresented but have been omitted for purposes of brevity.

[0036] As used herein, the terms “comprising” and “including,” and variations thereof, shall be construed as synonymous and open-ended, unless otherwise indicated. A list of elements following the transitional phrases comprising or including is a non exclusive list, such that elements in addition to those specifically recited in the list may also be present.

[0037] The terms “substantial,” “substantially,” and variations thereof as used herein are intended to note that a described feature is equal or approximately equal to a value or description. For example, a “substantially planar” surface is intended to denote a surface that is planar or approximately planar. Moreover, “substantially” is intended to denote that two values are equal or approximately equal. In some embodiments, “substantially” may denote values within about 10% of each other, such as within about 5% of each other, or within about 2% of each other.

[0038] As used herein, “refractory” refers to non-metailic materials having chemical and physical properties making them applicable for structures, or as components of systems, that are exposed to environments above 538°C.

[0039] Shown in FIG. 1 is an exemplary glass manufacturing apparatus 10. In some embodiments, the glass manufacturing apparatus 10 can comprise a glass melting furnace 12 including a melting vessel 14. In addition to melting vessel 14, glass melting furnace 12 can optionally include one or more additional components such as heating elements (e.g., combustion burners and/or electrodes) configured to heat raw material and convert the raw material into molten glass. For example, melting vessel 14 may be an electrically -boosted melting vessel, wherein energy is added to the raw material through both combustion burners and by direct heating, wherein an electrical current is passed through the raw material, the electrical current thereby adding energy via Joule heating of the raw material. [0040] In further embodiments, glass melting furnace 12 can include other thermal management devices (e.g., isolation components) that reduce heatloss from the melting vessel. In still further embodiments, glass melting furnace 12 can include electronic and/or electromechanical devices that facilitate melting of the raw material into a glass melt. Glass melting furnace 12 can include support structures (e.g., support chassis, support member, etc.) or other components.

[0041] Melting vessel 14 can beformedfrom a refractory material, such as a refractory ceramic material, for example a refractory ceramic material comprising alumina or zirconia, although the refractory ceramic material can comprise other refractory materials, such as yttrium (e.g., yttria, yttria-stabilized zirconia, yttrium phosphate), zircon (ZrSi0 ) or alumina-zirconia-silica or even chrome oxide, used either alternatively or in any combination. In some examples, melting vessel 14 may be constructed from refractory ceramic bricks.

[0042] In some embodiments, glass melting furnace 12 can be incorporated as a component of a glass manufacturing apparatus configured to fabricate a glass article, for example a glass ribbon, although in further embodiments, the glass manufacturing apparatus can be configuredto form other glass articles without limitation, such as glass rods, glass tubes, glass envelopes (for example, glass envelopes for lighting devices, e.g., light bulbs) and glass lenses, although many other glass articles are contemplated. In some examples, the melting furnace may be included in a glass manufacturing apparatus comprising a slot draw apparatus, a float bath apparatus, a down-draw apparatus (e.g., a fusion down draw apparatus), an up-draw apparatus, a pressing apparatus, a rolling apparatus, a tube drawing apparatus or any other glass manufacturing apparatus that would benefit from the present disclosure. By way of example, FIG. 1 schematically illustrates glass melting furnace 12 as a component of a fusion down-draw style glass manufacturing apparatus 10 for fusion drawing a glass ribbon for subsequent processing into individual glass sheets or rolling the glass ribbon onto a spool. As used herein, fusion drawing comprises flowing molten glass over converging surfaces of a forming body, wherein the resulting two streams of molten material join, or “fuse,” at the bottom of the forming body along the line of convergence.

[0043] Glass manufacturing apparatus 10 can optionally include an upstream glass manufacturing apparatus 16 positioned upstream of melting vessel 14. In some examples, a portion of, or the entire upstream glass manufacturing apparatus 16, can be incorporated as part of the glass melting furnace 12.

[0044] As shown in the embodiment illustrated in FIG. 1, upstream glass manufacturing apparatus 16 can include a raw material storage bin 18, a raw material delivery device 20 and a motor 22 connected to raw material delivery device 20. Raw material storage bin 18 can be configured to store a quantity of raw material 24 that can be fed into melting vessel 14 of glass melting furnace 12 through one or more feed ports, as indicated by arrow26. Raw material 24 typically comprises one or more glass forming metal oxides and one or more modifying agents. In some examples, raw material delivery device 20 can be powered by motor 22 to deliver a predetermined amount of raw material 24 from raw material storage bin 18 to melting vessel 14. In further examples, motor 22 can power raw material delivery device 20 to introduce raw material 24 at a controlled rate based on a level of molten glass sensed downstream from melting vessel 14 relative to a flow direction of the molten glass. Raw material 24 within melting vessel 14 can thereafter be heated to form molten glass 28. Typically, in an initial melting step, raw material is added to the melting vessel as particulate, for example as various “sands.” Raw material 24 can also include scrap glass (i.e. cullet) from previous melting and/or forming operations. Combustion burners are typically used to begin the melting process. In an electrically boosted melting process, once the electrical resistance of the raw material is sufficiently reduced, electric boost can begin by developing an electrical potential between electrodes positioned in contact with the raw material, thereby establishing an electrical current through the raw material, the raw material typically entering, or in, a molten state. As used herein, the resultant molten material shall be referred to as molten glass.

[0045] Glass manufacturing apparatus 10 can also optionally include a downstream glass manufacturing apparatus 30 positioned downstream of glass melting furnace 12 relative to a flow direction of molten glass 28. In some examples, a portion of downstream glass manufacturing apparatus 30 may be incorporated as part of glass melting furnace 12. However, in some instances, first connecting conduit 32 discussed below, or other portions of the downstream glass manufacturing apparatus 30, can be incorporated as part of the glass melting furnace 12.

[0046] Downstream glass manufacturing apparatus 30 can include a first conditioning (i.e. processing) chamber, such as fining vessel 34, located downstream from melting vessel 14 and coupled to melting vessel 14 by way of the above-referenced first connecting conduit 32. In some examples, molten glass 28 may be gravity fed from melting vessel 14 to fining vessel 34 by way of first connecting conduit 32. For instance, gravity may drive molten glass 28 through an interior pathway of first connecting conduit 32 from melting vessel 14 to fining vessel 34. Accordingly, first connecting conduit 32 provides a flow path for molten glass 28 from melting vessel 14 to fining vessel 34. It should be understood, however, that other conditioning chambers may be positioned downstream of melting vessel 14, for example between melting vessel 14 and fining vessel 34. In some embodiments, a conditioning chamber can be employed between the melting vessel and the fining chamber. For example, molten glass from a primary melting vessel can be further heated in a secondary melting (conditioning) vessel or cooled in the secondary melting vessel to a temperature lower than the temperature of the molten glass in the primary melting vessel before entering the fining chamber.

[0047] As described previously, bubbles may be removed from molten glass 28 by various techniques. For example, raw material 24 may include multivalent compounds (i.e. fining agents) such as tin oxide that, when heated, undergo a chemical reduction reaction and release oxygen. Other suitable fining agents can include without limitation arsenic, antimony, iron, and/or cerium, although the use of arsenic and antimony, owing to their toxicity, may be discouraged for environmental reasons in some applications. Fining vessel 34 is heated, for example to a temperature greater than the melting vessel interior temperature, thereby heating the fining agent. Oxygen produced by the temperature-induced chemical reduction of one or more fining agents included in the molten glass rise through the molten glass within the fining vessel can coalesce or diffuse into bubbles produced during the melting process. The enlarged gas bubbles with increased buoyancy can then rise to a free surface of the molten glass within the fining vessel and thereafter be vented out of the fining vessel.

[0048] The downstream glass manufacturing apparatus 30 can further include another conditioning chamber, such as mixing apparatus 36, for example a stirring vessel, for mixing the molten glass that flows downstream from fining vessel 34. Mixing apparatus 36 can be used to provide a homogenous glass melt composition, thereby reducing chemical or thermal inhomogeneities that may otherwise exist within the molten glass exiting the fining chamber. As shown, fining vessel 34 may be coupled to mixing apparatus 36 by way of a second connecting conduit 38. In some embodiments, molten glass 28 can be gravity fed from the fining vessel 34 to mixing apparatus 36. For instance, gravity may drive molten glass 28 through an interior pathway of second connecting conduit 38 from fining vessel 34 to mixing apparatus 36. Typically, the molten glass within mixing apparatus 36 includes a free surface, with a free (e.g., gaseous) volume extending between the free surface and a top of the mixing apparatus. While mixing apparatus 36 is shown downstream of fining vessel 34 relative to a flow direction of the molten glass, mixing apparatus 36 may be positionedupstream from fining vessel 34 in other embodiments. In some embodiments, downstream glass manufacturing apparatus 30 may include multiple mixing apparatus, for example a mixing apparatus upstream from fining vessel 34 and a mixing apparatus downstream from fining vessel 34. When used, multiple mixing apparatus may be of the same design, or they may be of a different design from one another. In some embodiments, one or more of the vessels and/or conduits can include static mixing vanes positioned therein to promote mixing and subsequent homogenization of the molten material. [0049] Downstream glass manufacturing apparatus 30 can further include another conditioning chamber such as delivery vessel 40 located downstream from mixing apparatus 36. Delivery vessel 40 can condition molten glass 28 to be fed into a downstream forming device. Forinstance, delivery vessel 40 can act as an accumulator and/or flow controller to adjust and/or provide a consistent flow of molten glass 28 to forming body 42 by way of exit conduit 44. The molten glass within delivery vessel 40 can, in some embodiments, include a free surface, wherein a free volume extends upward from the free surface to a top of the delivery vessel. As shown, mixing apparatus 36 can be coupled to delivery vessel 40 by way of third connecting conduit 46. In some examples, molten glass 28 can be gravity fed from mixing apparatus 36 to delivery vessel 40. For instance, gravity can drive molten glass 28 through an interior pathway of third connecting conduit 46 from mixing apparatus 36 to delivery vessel 40. [0050] Downstream glass manufacturing apparatus 30 can further include forming apparatus 48 comprisingthe above-referenced formingbody 42, including inlet conduit 50. Exit conduit 44 can be positioned to deliver molten glass 28 from delivery vessel 40 to inlet conduit 50 of forming apparatus 48. Forming body 42 in a fusion down- draw glass making apparatus can comprise a trough 52 positioned in an upper surface of the formingbody, and opposing converging forming surfaces 54 that converge in a draw direction 56 along a bottom edge (root) 58 of the formingbody. Molten glass delivered to formingbody trough 52 via delivery vessel 40, exit conduit 44 and inlet conduit 50 overflows the walls of trough 52 and descends alongthe converging forming surfaces 54 as separate flows of molten glass. The separate flows of molten glass join below and along the root 58 to produce a single ribbon 60 of molten glass that is drawn in draw direction 56 from root 58 by applying a downward tension to the glass ribbon, such as by gravity and/or counter-rotating and opposing pulling rolls (See FIG. 2), to control the dimensions of the glass ribbon as the molten material cools and a viscosity of the material increases. Accordingly, glass ribbon 60 goes through a viscoelastic transition to an elastic state and acquires mechanical properties that give glass ribbon 60 stable dimensional characteristics.

[0051] To ensure the glass forming environment remains stable during the forming process, forming body 42 and at least a portion of the glass ribbon travel path below the forming body can be contained within an enclosure 64 with an open bottom. [0052] Glass ribbon 60 may, in some embodiments, be separated into individual glass sheets 66 by a glass separation apparatus 68. In some embodiments, the glass ribbon may be wound onto spools and stored for further processing.

[0053] Components of downstream glass manufacturing apparatus 30, including any one or more of connecting conduits 32, 38, 46, fining vessel 34, mixing apparatus 36, delivery vessel 40, exit conduit 44, or inlet conduit 50 may be formed from a precious metal. Suitable precious metals include platinum group metals selected from the group consisting of platinum, iridium, rhodium, osmium, ruthenium and palladium, or alloys thereof. For example, downstream components of the glass manufacturing apparatus may be formed from a platinum-rhodium alloy includingfrom about 70% to about 90% by weight platinum and about 10% to about 30% by weight rhodium. However, other suitable metals for forming downstream components of the glass manufacturing apparatus can include molybdenum, rhenium, tantalum, titanium, tungsten, and alloys thereof.

[0054] Although components of glass manufacturing apparatus 10 are shown and described as fusion downdraw glass making components, principles of the present disclosure can be applied to a wide variety of glass making processes. For example, melting vessels according to embodiments of the present disclosure can be used in such diverse glass making processes as fusion processes, slot draw processes, rolling processes, pressing processes, float processes, tube drawing processes, and so forth. [0055] To meet production demands, manufacturers have worked to extend the operational capacity and overall lifetime of glass melting operations. For example, replacement of tin electrodes with molybdenum electrodes in the melting vessel has prolonged the time between electrode replacement, thereby placing additional burden on the longevity of the melting vessel itself. To wit, in a conventional installation, the melting vessel typically outlived the electrodes. When the electrodes were sufficiently consumed, the melting campaign was terminated, and the melting vessel rebuilt and new electrodes. With an increase in electrode longevity, the lifetime of the melting vessel sets the term of the melting campaign. Accordingly, to prolong the melting campaign, methods of extending the melting vessel life are the determining factor for campaign duration.

[0056] FIGS. 2 and 3 depict perspective and top views of an exemplary melting vessel 14, respectively. As previously noted, melting vessel 14 comprises refractory walls, for example multiple courses of precisely cut ceramic bricks or larger blocks. The refractory bricks or blocks are formed from refractory materials such as alumina, zirconia, or another suitable ceramic refractory material. The use of a refractory mortar is optional, and in some embodiments, the melting vessel can be formed without the use of mortar. Typically, the melting vessel walls can comprise first side wall 100, second side wall 102, a backwall 104, a front wall 106, a floor or bottom wall 108 (see FIG. 3), and a roof structure, for example an arched roof structure overtop and resting on the walls, the roof structure covering an interior volume of the melting vessel formed by the walls, the bottom wall, and the roof structure. More specifically, the melting vessel can include lower wall portions that form an enclosure or pool 110 for holding raw materials which, when melted, form the molten glass 28. These walls come into direct contact with the molten glass and can be described as glass contact walls. Additionally, the various refractory walls of the melting vessel can comprise upper wall portions that form a superstructure overtop the lower wall portions.

[0057] In various embodiments, the upper wall portions can be separated from the lower wall portions by one or more steel members 112 configured to bear the weight of the upper wall portions and the roof structure. For purposes of description and not limitation, the lower wall portions will be referred to hereinafter as comprising first lower side wall 100a, second lower side wall 102a, lower back wall 104a, and lower front wall 106a. The lower wall portions are disposed on bottom wall 108. Walls of the superstructure are hereinafter referred to as first upper side wall 100b overtop the first lower side wall 100a, second upper sidewall 102b overtop second lower side wall 102a, upper back wall 104b overtop the lower back wall 104a, and upper front wall 106b overtop lower front wall 106a. The roof or ceiling is positioned overtop of and supported by the upper sidewalls 100b, 102b, and the upper back and front walls 104b, 106b, respectively, and is hereinafter referred to as crown 114. Crown 114 may also be constructed from refractory bricks or blocks. The refractory bricks or blocks of crown 114 may be formed into an arch shape using traditional masonry techniques for forming arches and/or vaults.

[0058] In accordance with some embodiments, and as shown in FIG. 2, openings 116 may be provided in first and second lower side walls 100a, 102a to accommodate a plurality of electrodes 118 that extend through openings 116 into molten glass 28. Electrodes 118 are supplied with an electric current that flows through and heats the molten glass. However, in various other embodiments, as shown in FIG. 3, electrodes 118 may instead extend into the molten glass enclosed by the refractory glass contact walls through openings in bottom wall 108. In various embodiments, electrodes 118 may comprise tin (e.g., tin oxide), or molybdenum.

[0059] Upper side walls 100b, 102b may include openings 120 that accommodate fuel- oxygen (fuel-oxy) burners 122. The fuel-oxy burners can be used to perform initial melting of the batch material during the start of a melting campaign, and to maintain a predetermined temperature or temperature range in the gaseous volume above molten glass 28 and enclosed by the superstructure during normal melting operations.

[0060] Upper back wall 104b includes one or more openings 124 configured to receive batch material from rawmaterial delivery device 20, the rawmaterial enteringinto pool 110 through the one or more openings 124. On the other hand, front lower wall 106a includes connecting conduit 32 through which molten glass within melting vessel 14 can pass to downstream process equipment, e.g., downstream glass manufacturing apparatus 30.

[0061] Melting vessel 14 can be enclosed in a cage of structural members, e.g., exoskeleton 125 that helps support the weight of the melting vessel and provide rigidity to the refractory structure. Metal grating panels, for example steel grating panels, can be pressed against the first and second lower side walls, the lower front wall, and/or the lower back wall by adjustable pressurebolts coupledto the building structural members or structural members of the exoskeleton (see FIG. 5), the pressure bolts engaging with the metal grating panels by way of pads between the grating panels and the pressure bolts. The metal grating panels provide a counter force against the lower side walls, the lower front wall, and the lower back wall designed to counter the outward pressure exerted against the inside of the walls by the molten glass. [0062] In accordance with embodiments of the present disclosure, melting vessel 14 may further comprise cooling panels, wherein a cooling fluid is flowed through passages in the cooling panels to cool one or more of the lower melting vessel walls. In addition to cooling the melting vessel walls, e.g., the refractory glass contact surfaces, the coolingpanels, like the steel grating panels, can serve a structural function by reinforcing the refractory materials used to construct the melting vessel.

[0063] Referring to FIG. 5, a portion of first lower sidewall 100a is depicted. First lower side wall 100a includes one or more metal grating panels 128 disposed against the first lower sidewall and held in place with a combination of pressure bolts 130 and bracing members 132 (see FIG. 5). Bracing members 132 are attached to one or both of upper cross member 134 and/or lower cross member 136, such as hy bolts or other suitable fasteners. In some embodiments, bracing members 132 can be welded to the cross members. Bracing members 132, upper cross member 134, and/or lower cross member 136 can be part of the building structure, for example the building structural steel, or attached thereto, or may be part of the melting vessel exoskeleton, or attached thereto.

[0064] Pressure bolts 130 are coupled to bracing members 132 and pressed against metal grating panels 128, thereby pressing the metal grating panels against the melting vessel walls. For example, in various embodiments, pressure bolts 130 comprise external threads, wherein the pressure bolts are coupled to the bracing members via threaded fasteners, e.g., nuts. This can be accomplished, for example, by providing flanges 138 attached to bracingmembers 132, such as by welding, the flanges extending outward from the bracing members. The flanges can include apertures through which the threaded pressure bolts 130arepassed. Apairofnuts 140, 142(seeFIG. 8)threaded onto the pressure bolts on each side of a flange 138 secure the pressure bolt to the flange and bracing member. Pressure against metal grating panels 128 can be varied by adjusting nuts 140, 142 on pressure bolts 130, thereby advancing the pressure bolts toward first lower side wall 100a or retracting the pressure bolts away from first lower side wall 100a, and thus adding or relieving pressure against the cooling panel and the first lower side wall. Each pressure bolt may be provided with an engagement foot 144 positioned between the bolt itself and a metal grating panel to extend the surface area over which the pressure bolt acts on the metal grating panel. The engagement foot can be coupled to the pressure bolt, such as hy a ball joint that allows the engagement foot to self-orient (self-level) against the metal grating panel and account for any irregularities on the surface of the metal grating panel or the melting vessel wall, or with the pressure bolts. That is, if a longitudinal axis of a pressure bolt is not orthogonal to the metal grating panel, for example due to a small misalignment of the refractory block makingup the melting vessel, the engagement foot can accommodate the angular offset. Because the refractory material of melting vessel 14 is electrically conductive, and electrical energy is used to heat the molten material contained therein, electrical isolation material 145 can be placed between each pressure bolt engagement foot 144 and metal grating panels 128 to electrically isolate the melting vessel and the metal grating panel from the surrounding metal supportmembers, e.g., the exoskeleton and/or building steel that might otherwise become electrically energized and pose a safety hazard to personnel.

[0065] In some embodiments, upper cross-member 134 and/or lower cross-member 136 may include flanges and pressure bolts to maintain the metal grating panels in contact with first lower wall 100a.

[0066] In accordance with embodiments disclosed herein and as shown in FIG. 5, the melting vessel further comprises one or more cooling panels 200. Each cooling panel 200 can be positioned against a wall of the melting vessel, such as first lower side wall 100a shown in FIG. 5, in the same manner as a metal grating panel 128, using pressure bolts 130, engagement feet 144, and electrically isolating material 145 to electrically isolate the melting vessel and cooling panel from the surrounding metal support members, e.g., bracing members 132. That is, a cooling panel 200 is positioned between a melting vessel wall, for example first lower side wall 100a, and one or more pressure bolts 130. The pressure bolts are coupled to bracing member 132 and can be adjusted by advancing or retracting pressure bolts 130 relative to the bracing member to apply sufficient pressure to a cooling panel to maintain the cooling panel in contact with the melting vessel wall and/or counter the force of the molten glass on the opposite side of the wall.

[0067] An exemplary cooling panel 200 is depicted in FIGS. 6-8. Cooling panel 200 comprises a base portion 202 and a cover portion 204. In some embodiments, base portion 202 and cover portion 204 can be permanently attached, for example by welding. However, in further embodiments, cover portion 204 can be configured to be removably fixed to base portion 202 using suitable fasteners 205 (e.g., bolts, screws). A gasket 208 can be positioned between base portion 202 and cover portion 204 to prevent leakage. Base portion 202 and/or cover portion204 may be formedfrom a high temperature corrosion-resistant material, such as stainless steel.

[0068] FIG. 7 is a top view of base portion 202 with cover portion 204 removed showing an interior cooling passage 210 that extends within base portion 202 between an inlet port 212 and an outlet port 214 (see FIG. 8) arranged on cover portion 204. That is, cooling passage 210 extends in a zig-zag fashion from a location within base portion 202 opposite inlet port 212 when cover portion 204 is attached to base portion 202, to an ending position within base portion 202 opposite outlet port 214. Cooling passage 210 may be a separate cooling member positioned inside the cooling panel, for example a stainless-steel tube that couples to inlet port 212 and outlet port 214. However, in further embodiments, the interior passage can be machined into one of base portion 202 or cover portion 204 such that interior cooling passage 210 is integral with cooling panel 200 (e.g., base portion 202). In the embodiment shown, cooling passage 210 is milled into base portion 202 leaving a plurality walls 216 (e.g., baffles) extending in an alternating manner from opposing interior side walls of the base portion. Walls 216 are arranged suchthatthe walls extendpast a centerline axis 218 of the base or cover portion so that the interior cooling passage 210 so formed is of a serpentine (e.g., zig-zag) shape to increase the length of the coolingpassagethe cooling fluid 220 traverses, thereby increase the cooling capacity of cooling panel 200. To reduce corrosion, the cooling panel base portion and cover portion can be made from stainless-steel or other high temperature corrosion-resistant material.

[0069] In various embodiments, cooling panel 200 can be provided with one or more a monitoring ports 222 for monitoring a parameter of the cooling fluid. For example, a monitoring device 224 (e.g., a thermocouple, see FIG. 9) may be inserted into cooling panel 200 through monitoring port 222. In some embodiments, monitoring port 222 may extend through an entire thickness of cover portion 204 or base portion 202 such that monitoring device 224 can be inserted into contact with the cooling fluid 220 flowing through cooling passage 210. Alternatively, the monitoring port may be positioned in a side of base portion 202. The one or more monitoring devices 224 can be in electrical communication with a process controller or other suitable control device (not shown) configuredto adjust a temperature and/or flow rate of coolingfluidthrough the cooling panel.

[0070] In various embodiments, cooling fluid 220 can be water, although in other embodiments, cooling fluid 220 can be a gas, such as air. In some embodiments, the cooling panel can comprise an open circuit cooling system wherein cooling fluid 220 is provided, for example, from a municipal source, such as a municipal water supply, flowed through the cooling panel along cooling passage 210, then discarded as waste. However, in other embodiments, the cooling panel can comprise a closed-circuit cooling system where cooling fluid, e.g., water, is circulated between an external heat exchanger that provides chilled cooling fluid. The chilled cooling fluid 220 is flowed through the coolingpanel, such ashy one or more coolingfluid pumps. The nowheated coolingfluid is then circulated from the coolingpanel to the heat exchanger to be cooled again and returned to the cooling panel, or another piece of process equipment.

[0071] In some embodiments, cooling fluid 220 can be routed to and from multiple cooling panels simultaneously through suitable inlet and outlet headers. Coolant lines to and from each cooling panel can be provided with valves, either manual or remote- operated, to allow isolation of a particular cooling panel, for example if a leak occurs, or the cooling panel must be removed or replaced. For example, FIG. 5 shows cooling panels arranged in pairs (two pair shown), wherein each cooling panel 200 of a pair of cooling panels is supplied with coolingfluid from a coolant supply header 226 suppling both cooling panels with cooling fluid through individual supply lines 228 extending between supply header 226 and an inlet port 212 of the respective cooling panel. Each supply line 228 can be provided with an isolation valve 230 arranged to shut off flow of cooling fluid to the respective cooling panel. Supply header 226 is provided with cooling fluid 220 through main supply line 231.

[0072] Additionally, each coolingpanel 200 ofapairof coolingpanels is provided with an individual return line 232 extending between a respective outlet port 214 of each cooling panel and a return header 234. Return header 234 can be arranged in fluid communication with a downstream collection apparatus (not shown) through a main return line 236, wherein the collection apparatus may, for example, process the cooling fluid for resupply to the cooling panels. For example, the collection apparatus may filter the coolant, cool the cooling fluid, or treat the cooling fluid by adding any one or more conditioning additives (e.g., anticorrosion materials). In some embodiments, heat can be extracted from the heated cooling fluid after leaving the cooling panel, for example in a heat exchanger, and the extracted heat used in further processes. As is the case with the cooling fluid supply, each return line 232 can be provided with an isolation valve 230 configured to shut off the return flow of coolant from the respective cooling panel. Thus, should it be necessary, for example in the case of a leak in one of the cooling panels, the leaky cooling panel can be isolated by closing the associated isolation valves in the supply and return lines and removing the defective cooling panel without the need to cease flow through another one of the cooling panels connected to the same supply and return headers. The isolation valves may be manual isolation valves or remotely controlled isolation valves.

[0073] One or more cooling panels 200 may be provided on any one or more of the lower walls of melting vessel 14, including the lower sidewalls, the lower front wall or the lower back wall. The modular design of the individual metal grating panels 128 and the cooling panels 200 allows for replacement of a selected grating with another grating, or with a cooling panel as the need arises, during operation of the glass manufacturing apparatus, i.e., while the melting vessel is in operation and molten glass is being actively formed. To aid in installation of a cooling panel, the cooling panel, e.g., cover portion 204, can be provided with one or more handles 238.

[0074] As shown in FIG. 9, cooling panel 200 can be placed in direct contact with at least one of first or second lower side walls 100a or 102a, lower back wall 204a, or lower front wall 206a. A metal grating panel 128 is neither placed between cooling panel 200 and the respective refractory wall side or over the cooling panel. Accordingly, the coolingpanel 200 functions both as a cooling device and a reinforcing member that reinforces the respective refractory wall. In various embodiments, one or more metal grating panels 128 and one or more cooling panels 200 may be used to support a lower wall portion of melting vessel 14.

[0075] In some embodiments, as best seen in FIG. 6, base portion 202 may include recess 240 positioned on back surface 242 (the surface in contact with the wall of the melting vessel). For example, a conformable thermally conductive material 244, for example a compressible metal mesh material, such as an expanded metal mesh, can be placed in recess 240 and sandwiched between the coolingpanel and the melting vessel wall. The conformable thermally conductive material 244 may provide sufficient flexibility to conform to the melting vessel wall, thereby enhancing thermal conduction between the cooling panel and the melting vessel wall. The conformable thermally conductive material 244 may have an initial thickness greater than a depth of recess 240 so that when cooling panel 200 is placed against the melting vessel wall and forced against it by the pressure of the one or more pressure bolts, the conformable thermally conductive material 244 compresses and conforms to the shape of the melting vessel wall. [0076] Each cooling panel 200 may be arranged such that the flow of cooling fluid 220 through the cooling panel is in an upward direction, opposite the direction of gravity, thereby both complimenting the natural tendency of the cooling fluid to move upward when heated (by heat exchange with the hot refractory wall) and to prevent stagnant bubble formation in cooling passage 210. However, in further embodiments, the flow of cooling fluid can be downward. For example, in some embodiments, input port 212 can be positioned in a top half of the cooling panel and outlet port 214 can be positioned in a bottom half of the cooling panel. In still further embodiments, the inlet port 212 can be positioned on or adjacent a first side edge of the cooling panel and the outlet port 214 positioned on or adjacent a second edge of the cooling panel opposite the first edge such that flow of the cooling fluid is laterally from the first side to the second side of the cooling panel.

[0001] As described above, each cooling panel 200 may be held in position against a lower refractory wall by one or more pressure bolts that engage with cooling panel 200 and bracing member 132, each pressure bolt 130 extending between bracing member 132 and an engagement foot 144 in contact with the coolingpanel. Pressure may be applied to engagement foot 144, and coolingpanel 200, by loosening first, outer nut 140 (turning first nut 140 sothatthe firstnut 140 moves away frombracingmember 132 and away from the coolingpanel), then a second, inside nut 142 is rotated so second nut 142 moves against bracing member 132 until the desired pressure on cooling panel 200 is achieved, then first nut 140 is rotated until the first nut is tight against bracing member 132. In additional or alternative embodiments, the pressure bolt may include a spring elementto provide flexibility to the coupling between the coolingpanel and the bracing member. For example, in some embodiments, a pressure bolt 300 may be used. Referring to FIG. 10, an exemplary pressure bolt 300 is schematically depicted. Pressure bolt 300 generally comprises a threaded rod 302 that extends through a body 304. Body 304 contains a plurality of disc springs 306, such as Bellville washers or the like, which bias threaded rod 302 in the direction indicated by arrow 308. A first end of the threaded rod 302 includes tensioning nut 310 and the second end of the threaded rod 302 includes an engagement foot 312. Pressure bolt 300 may also include a jam nut 314 positioned on threaded rod 302, which can be advanced against body 304 to prevent compression of disc springs 306. Pressure bolt 300 maybe coupled to bracing member 132 in a manner similar to pressure bolt 130. [0077] It will be apparent to those skilled in the art that various modifications and variations can be made to embodiments of the present disclosure without departing from the spirit and scope of the disclosure. Thus, it is intended that the present disclosure cover suchmodificationsandvariationsprovided they come within the scope of the appended claims and their equivalents.

Claims

What it claimed is:

1. A glass manufacturing apparatus, comprising: a melting vessel comprising a refractory glass contact wall; a cooling panel configured to receive a cooling fluid through an inlet port and to expel the cooling fluid through an outlet port; and wherein the cooling panel is in contact with and urged against the refractory glass contact wall by a pressure bolt in contact with the cooling panel.

2. The glass manufacturing apparatus of claim 1 , wherein the inlet port is positioned in a bottom half of the cooling panel and the outlet port is positioned in a top half of the cooling panel.

3. The glass manufacturing apparatus of claim 1, wherein the refractory glass contact wall comprises a side wall of the melting vessel.

4. The glass manufacturing apparatus of claim 1 , wherein the cooling panel comprises a serpentine passage extending therein between the inlet port and the outlet port.

5. The glass manufacturing apparatus of claim 4, wherein the cooling panel comprises a base portion and a cover portion, the serpentine passage machined into the base portion and the cover portion attached to the base portion.

6. The glass manufacturing apparatus of claim 5, wherein the base portion is in contact with the refractory glass contact wall.

7. The glass manufacturing apparatus of claim 6, wherein the base portion comprises a back surface including a recess formed therein, and wherein a conformable thermally conductive material is positioned in the recess between the cooling panel and the refractory glass contact wall.

8. The glass manufacturing apparatus of claim 1 , wherein the cooling panel comprises at least one thermocouple.

9. The glass manufacturing apparatus of claim 1, wherein the melting vessel comprises a plurality of cooling panels in contact with and urged against the refractory glass contact wall, the plurality of cooling panels supplied with the cooling fluid through a single cooling fluid header.

10. The glass manufacturing apparatus of claim 9, wherein each cooling panel is supplied from the cooling fluid header through a coolant line, the coolant line of each cooling panel including an isolation valve.

11. The glass manufacturing apparatus of claim 1, wherein the cooling panel is provided with a handle.

12. The glass manufacturing apparatus of claim 1, wherein the pressure bolt is positioned between a bracing member and the cooling panel, the pressure bolt coupled to the bracing member.

13. The glass manufacturing apparatus of claim 1, further comprising a metal grating panel in contact with and urged against the refractory glass contact wall.

14. The glass manufacturing apparatus of claim 13, wherein the metal grating panel is positioned below the cooling panel.

15. The glass manufacturing apparatus of claim 14, wherein the metal grating panel is supported at least in part by a refractory block positioned beneath the metal grating.

16. The glass manufacturing apparatus of claim 15, wherein the melting vessel comprises a second metal grating panel in contact with and urged against the refractory glass contact wall, the second metal grating panel positioned above the cooling panel.