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Systems and methods for making foamed glass using submerged combustion

  • US 8,997,525 B2
  • Filed: 10/07/2011
  • Issued: 04/07/2015
  • Est. Priority Date: 06/17/2010
  • Status: Active Grant
First Claim
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1. A submerged combustion foamed glass manufacturing system comprising:

  • a submerged combustion melter comprising a melting zone defined by a floor, a ceiling, and a substantially vertical wall connecting the floor and ceiling at a perimeter of the floor and ceiling, the melting zone having a molten glass outlet, the melter devoid of a refining zone, the melting zone having a feed inlet for receiving at least one partially vitrifiable material through a batch feed chute, the batch feed chute and the molten glass outlet positioned at opposing ends of the melting zone, the melting zone having an expanding zone beginning at the inlet, and extending to an intermediate location relative to the opposing ends, and a narrowing zone extending from the intermediate location to the molten glass outlet, and a plan view shape selected from the group consisting of;

    i) defined by first and second trapezoids sharing a common base positioned at the intermediate location and substantially perpendicular to a longitudinal axis of the melter, the first trapezoid having a side parallel to the base and positioned at the feed inlet, the second trapezoid having a side parallel to the base and positioned at the molten glass outlet; and

    ii) a non-symmetrical plan about an axis substantially perpendicular to a longitudinal axis of the melter, wherein the substantially vertical wall in the expanding zone and the narrowing zone is non-linear;

    and a plurality of submerged combustion burners, at least some of which are positioned to direct combustion products into the expanding zone and the narrowing zone under a level of molten glass in the expanding zone and the narrowing zone,the melter molten glass outlet fluidly connected to an intermediate stage positioned between the melter molten glass outlet and a conveyor, the intermediate stage fluidly connected to the conveyor, the conveyor comprising heat-resistant components and devoid of gas injectors, the conveyor fluidly connected to a processing apparatus downstream of the conveyor, andwherein the intermediate stage comprises a refractory or refractory-lined channel having width, depth, and length, the refractory or refractory-lined channel comprising one or more gas injectors positioned to deliver gas through a bottom of the refractory or refractory-lined channel.

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