Process of using a submerged combustion melter to produce hollow glass fiber or solid glass fiber having entrained bubbles, and burners and systems to make such fibers

• US 9,032,760 B2
• Filed: 07/03/2012
• Issued: 05/19/2015
• Est. Priority Date: 07/03/2012
• Status: Active Grant

• Current Assignee: Johns Manville Corporation (Berkshire Hathaway Incorporated)
• Original Assignee: Johns Manville Corporation (Berkshire Hathaway Incorporated)
• Inventors: Charbonneau, Mark William, McHugh, Kevin Patrick
• Primary Examiner(s): FRANKLIN, JODI COHEN
• Application Number:
  US13/540,771
• Publication Number:
  US 20140007623A1
• Time in Patent Office: 1,050 Days
• Field of Search: 65377-485
• US Class Current: 65/380
• CPC Class Codes: C03B 2201/00 Type of glass produced
• CPC Class Codes: C03B 2203/14 Non-solid, i.e. hollow products, e.g. hollow clad or with core-clad interface
• CPC Class Codes: C03B 2203/16 Hollow core
• CPC Class Codes: C03B 2211/22 by direct combustion in the melt
• CPC Class Codes: C03B 2211/23 using oxygen, i.e. pure oxygen or oxygen-enriched air
• CPC Class Codes: C03B 2211/40 using oxy-fuel burners
• CPC Class Codes: C03B 2211/60 oxy-fuel burner construction
• CPC Class Codes: C03B 37/022 from molten glass in which the resultant product consists of different sorts of glass or is characterised by shape, e.g. hollow fibres , undulated fibres, fibres presenting a rough surface C03B37/025 takes precedence
• CPC Class Codes: C03B 37/07 Controlling or regulating C03B37/0253 takes precedence ; controlling or regulating in general G05
• CPC Class Codes: C03B 37/075 Manufacture of non-optical fibres or filaments consisting of different sorts of glass or characterised by shape, e.g. undulated fibres C03B37/022, C03B37/027, C03B37/028 take precedence; light guides G02B6/00
• CPC Class Codes: C03B 37/0756 Hollow fibres
• CPC Class Codes: C03B 5/193 using gas, e.g. bubblers
• CPC Class Codes: C03B 5/2353 by combustion with pure oxygen or oxygen-enriched air, e.g. using oxy-fuel burners or oxygen lances
• CPC Class Codes: C03B 5/2356 Submerged heating, e.g. by using heat pipes, hot gas or submerged combustion burners bubblers C03B5/193
• CPC Class Codes: C03B 7/02 Forehearths, i.e. feeder channels
• CPC Class Codes: F23C 2201/20 Burner staging
• CPC Class Codes: F23C 2201/301 with different fuels in stages
• CPC Class Codes: F23C 6/047 with fuel supply in stages
• CPC Class Codes: F23D 14/22 with separate air and gas feed ducts, e.g. with ducts running parallel or crossing each other
• CPC Class Codes: F23D 14/62 Mixing devices; Mixing tubes
• CPC Class Codes: F23D 14/78 : Cooling burner parts
• CPC Class Codes: H03F 1/3205 : in field-effect transistor amplifiers
• CPC Class Codes: H03F 1/56 : Modifications of input or output impedances, not otherwise provided for
• CPC Class Codes: H03F 2200/18 : the bias of the gate of a FET being controlled by a control signal
• CPC Class Codes: H03F 2200/21 : Bias resistors are added at the input of an amplifier
• CPC Class Codes: H03F 2200/211 : the input of an amplifier can be attenuated by a continuously controlled transistor attenuator
• CPC Class Codes: H03F 2200/213 : A variable capacitor being added in the input circuit, e.g. base, gate, of an amplifier stage
• CPC Class Codes: H03F 2200/222 : A circuit being added at the input of an amplifier to adapt the input impedance of the amplifier
• CPC Class Codes: H03F 2200/225 : the input circuit of an amplifying stage comprising an LC-network
• CPC Class Codes: H03F 2200/24 : the supply or bias voltage or current at the source side of a FET being continuously controlled by a controlling signal
• CPC Class Codes: H03F 2200/243 : A series resonance being added in series in the input circuit, e.g. base, gate, of an amplifier stage
• CPC Class Codes: H03F 2200/249 : A switch coupled in the input circuit of an amplifier being controlled by a circuit, e.g. feedback circuitry being controlling the switch
• CPC Class Codes: H03F 2200/27 : A biasing circuit node being switched in an amplifier circuit
• CPC Class Codes: H03F 2200/294 : the amplifier being a low noise amplifier [LNA]
• CPC Class Codes: H03F 2200/297 : the loading circuit of an amplifying stage comprising a capacitor
• CPC Class Codes: H03F 2200/301 : the loading circuit of an amplifying stage comprising a coil
• CPC Class Codes: H03F 2200/306 : the loading circuit of an amplifying stage being a parallel resonance circuit
• CPC Class Codes: H03F 2200/312 : the loading circuit of an amplifying stage comprising one or more switches
• CPC Class Codes: H03F 2200/387 : A circuit being added at the output of an amplifier to adapt the output impedance of the amplifier
• CPC Class Codes: H03F 2200/391 : the output circuit of an amplifying stage comprising an LC-network
• CPC Class Codes: H03F 2200/399 : A parallel resonance being added in shunt in the output circuit, e.g. base, gate, of an amplifier stage
• CPC Class Codes: H03F 2200/417 : A switch coupled in the output circuit of an amplifier being controlled by a circuit
• CPC Class Codes: H03F 2200/451 : the amplifier being a radio frequency amplifier
• CPC Class Codes: H03F 2200/48 : the output of the amplifier being coupled out by a capacitor
• CPC Class Codes: H03F 2200/489 : A coil being added in the source circuit of a common source stage, e.g. as degeneration means
• CPC Class Codes: H03F 2200/492 : A coil being added in the source circuit of a transistor amplifier stage as degenerating element
• CPC Class Codes: H03F 2200/495 : A parallel resonance circuit being added in the source circuit of a FET amplifier
• CPC Class Codes: H03F 2200/546 : A tunable capacitance being present in an amplifier circuit
• CPC Class Codes: H03F 2200/72 : the amplifier stage being a common gate configuration MOSFET
• CPC Class Codes: H03F 2200/75 : the amplifier stage being a common source configuration MOSFET
• CPC Class Codes: H03F 3/195 : in integrated circuits
• CPC Class Codes: H03F 3/72 : Gated amplifiers, i.e. amplifiers which are rendered operative or inoperative by means of a control signal
• CPC Class Codes: H03G 1/0029 : using FETs
• CPC Class Codes: H03G 1/0088 : using discontinuously variable devices, e.g. switch-operated
• CPC Class Codes: H03G 1/0094 : using switched capacitors
• CPC Class Codes: H03G 2201/106 : being attenuating element
• CPC Class Codes: H03G 2201/307 : being radio frequency signal
• CPC Class Codes: H03G 2201/504 : by summing selected parallel amplifying paths, i.e. more amplifying/attenuating paths summed together
• CPC Class Codes: H03G 3/001 : Digital control of analog signals
• CPC Class Codes: H03G 3/008 : Control by switched capacitors
• CPC Class Codes: H03G 3/10 : having semiconductor devices
• CPC Class Codes: Y02P 40/50 : Glass production, e.g. reusing waste heat during processing or shaping

Abstract

Processes and systems for producing glass fibers having regions devoid of glass using submerged combustion melters, including feeding a vitrifiable feed material into a feed inlet of a melting zone of a melter vessel, and heating the vitrifiable material with at least one burner directing combustion products of an oxidant and a first fuel into the melting zone under a level of the molten material in the zone. One or more of the burners is configured to impart heat and turbulence to the molten material, producing a turbulent molten material comprising a plurality of bubbles suspended in the molten material, the bubbles comprising at least some of the combustion products, and optionally other gas species introduced by the burners. The molten material and bubbles are drawn through a bushing fluidly connected to a forehearth to produce a glass fiber comprising a plurality of interior regions substantially devoid of glass.

Claims

1. A process comprising:

a) feeding at least one partially or wholly vitrifiable feed material into a feed inlet of a melting zone of a melter vessel comprising a floor, a ceiling, and a wall connecting the floor and ceiling at a perimeter of the floor and ceiling, the meter vessel comprising a feed opening in the wall or ceiling and an exit end comprising a melter exit structure for discharging molten material formed in the melting zone;

b) heating the at least one partially or wholly vitrifiable material with at least one burner directing combustion products of an oxidant and a first fuel into the melting zone under a level of the molten material in the zone, one or more of the burners configured to impart heat and turbulence to at least some of the molten material in the melting zone, producing a turbulent molten material comprising a plurality of bubbles suspended in the molten material, the bubbles comprising at least some of the combustion products;

c) discharging the molten material comprising bubbles from the melter vessel through the inciter exit structure into a forehearth having a plurality of bushings connected to the forehearth producing fibers of the same outside diameter, the process comprising controlling flow of the molten material comprising bubbles through the forehearth and bushings so that fibers produced through the bushings are substantially consistent in volume of regions devoid of glass, the controlling comprising inclining the forehearth at an angle to horizontal of no more than about 30 degrees to horizontal, the angle causing a distal end of the forehearth furthest from the melter exit structure to be raised above a horizontal plane, while a proximal end of the forehearth remains at a level equal to that of the melter exit; and

d) drawing the molten material comprising bubbles through the bushings to produce glass fibers comprising a plurality of interior regions substantially devoid of glass.

2. The process of claim 1 comprising controlling composition of the turbulent molten material and the bubbles suspended in the molten material by adjusting one or more of the burners.

3. The process of claim 2 comprising adjusting one or more parameters selected from the group consisting of composition of the first fuel, composition of the oxidant, composition of a third fluid injected through at least one of the burners, flow rate of the first fuel, flow rate of the oxidant, and flow rate of the third fluid.

4. The process of claim 3 wherein the adjusting one or more parameters is composition of a third fluid injected through at least one of the burners selected from the group consisting of feeding a composition comprising a second fuel, feeding a second oxidant, feeding a fluid other than a fuel or an oxidant, and combinations thereof.

5. The process of claim 1 comprising adjusting one or more of temperature of the molten material, flow rate of vitrifiable feed material, molten glass discharge rate, and degree of turbulence of the molten material to achieve an average bubble diameter in the molten material that is less than a diameter of the drawn fibers.

6. The process of claim 1 comprising controlling volume of individual regions substantially devoid of glass by adjusting volume of individual bubbles in the molten material.

7. A process comprising:

a) feeding at least one partially or wholly vitrifiable material into a feed inlet of a melting zone of a melter vessel comprising a floor, a ceiling, and a wall connecting the floor and ceiling at a perimeter of the floor and ceiling, the inciter vessel comprising a feed opening in the wall or ceiling and an exit end comprising a melter exit structure for discharging molten material formed in the melting zone;

b) heating the at least one partially or wholly vitrifiable material with at least one burner directing combustion products of an oxidant and a first fuel into the melting zone under a level of the molten material in the zone, one or more of the burners configured to impart heat and turbulence to at least some of the molten material in the melting zone, producing a turbulent molten material comprising a plurality of bubbles suspended in the molten material, the bubbles comprising at least some of the combustion products;

c) discharging the molten material comprising bubbles from the melter vessel through the melter exit structure into a forehearth;

d) drawing the molten material comprising bubbles through a plurality of bushings producing glass fibers each comprising a plurality of interior regions devoid of glass, the fibers having substantially same outside diameter; and

e) controlling flow of the molten material comprising bubbles through the forehearth and bushings so that fibers produced through the bushings are substantially consistent in volume of regions devoid of glass, the controlling comprising inclining forehearth at an angle to horizontal of no more than about 30 degrees, the angle causing a distal end of the forehearth to be raised above a horizontal plane, while a proximal end of the forehearth, remains at a level equal to that of the melter exit.

8. The process of claim 7 wherein the controlling comprises the bushings drawing off the molten material comprising bubbles in a configuration where a bushing most proximal to the melter exit structure draws at a lowest level in the forehearth and succeeding bushings draw molten material comprising bubbles at succeeding higher levels in the forehearth.

9. The process of claim 7 comprising controlling composition of the molten material by adjusting one or more of the burners.

10. The process of claim 9 comprising adjusting one or more parameters selected from the group consisting of composition of the first fuel, composition of the oxidant, composition of a third fluid injected through at least one of the burners, flow rate of the first fuel, flow rate of the oxidant, and flow rate of the third fluid.

11. The process of claim 10 wherein the adjusting one or more parameters is adjusting composition of the third fluid injected through at least one of the feeding of the third fluid is selected from the group consisting of feeding a composition comprising a second fuel, feeding a second oxidant, feeding a fluid other than a fuel or an oxidant, and combinations thereof.

12. A system comprising:

a) a melter vessel comprising a floor, a ceiling, and a wall connecting the floor and ceiling at a perimeter of the floor and ceiling, the melter vessel comprising a feed opening in the wall or ceiling and an exit end comprising a melter exit structure for discharging molten material formed in a turbulent melting zone, and one or more burners, at least one of which is positioned to direct combustion products into the turbulent melting zone under a level of turbulent molten material in the turbulent melting zone;

b) a forehearth fluidly connected to the meter exit structure without any intervening channel or component, the forehearth comprising a plurality of bushings configured to produce glass fibers each comprising a plurality of interior regions devoid of glass, the fibers having substantially same outside diameter, the forehearth inclined at an angle to horizontal of no more than about 30 degrees to horizontal, the angle causing a distal end of the forehearth furthest from the melter exit structure to be raised above a horizontal)lane, while a proximal end of the forehearth remains at a level equal to that of the melter exit.

13. The system of claim 12 wherein at least one of the burners comprises:

a first conduit comprising a first end, a second end, a longitudinal bore having a longitudinal axis, and an external surface;

a second conduit substantially concentric with the first conduit, the second conduit comprising a first end, a second end, and an internal surface;

the first and second conduits configured to form a primary annulus between the external surface of the first conduit and the internal surface of the second conduit;

a third substantially concentric conduit comprising a first end, a second end, and an internal surface, the internal surface of the third conduit forming, with an exterior surface of the second conduit, a secondary annulus external to the primary annulus;

one or more alternate gas tubes extending substantially longitudinally through one of the primary and the secondary annuli and comprising distal ends terminating in ports near the first end of the second conduit; and

one or more secondary fuel tubes extending substantially longitudinally through one of the primary and secondary annuli and comprising distal ends positioned near the first ends of the first and second conduits.

14. The system of claim 13 wherein the burner comprises one or more flow controllers on the primary conduit, one or more of the alternate gas tubes, and/or one or more of the secondary fuel tubes allowing adjustment of composition of the turbulent molten material and the bubbles suspended in the molten material.

15. The system of claim 12 wherein the melter vessel comprises:

a wall separating the inciter vessel into first and second turbulent melting zones;

the first turbulent melting zone comprising a first feed opening, a first plurality of burners positioned to direct combustion products into the first turbulent melting zone under a level of first turbulent molten material in the first turbulent melting zone, a first melter exit structure, and a first melting zone dam;

the second melting zone further comprising a second feed opening, a second plurality of burners positioned to direct combustion products into the second turbulent melting zone under a level of second turbulent molten material in the second turbulent melting zone, a second melter exit structure, and a second melting zone dam; and

wherein the first and second melter exits structures are fluidly connected to the forehearth.

16. The system of claim 12 comprising:

a first inciter vessel comprising a first feed opening, a first plurality of burners positioned to direct combustion products into a first turbulent melting zone under a level of first turbulent molten material in the first turbulent melting zone, a first melter exit structure for discharging first molten material into a first forehearth, and a first dam;

a second melter vessel comprising a second feed opening, a second plurality of burners positioned to direct combustion products into a second turbulent melting zone under a level of second turbulent molten material in the second turbulent melting zone, a second melter exit structure for discharging second molten material into a second forehearth, and a second dam; and

the first forehearth fluidly connected to the second forehearth by a distribution channel.