Methods and apparatus for recycling glass products using submerged combustion
First Claim
1. A method of recycling glass mat (18) materials, comprising:
- a) providing a source (16) of glass mat (18), wherein the glass mat (18) is selected from the group consisting of nonwoven and woven materials;
b) routing the glass mat (18) at a substantially consistent feed rate into a submerged combustion melter (2) through a slot (26) in the melter (2) and then directly into a well-mixed mass of molten glass (4) within the melter (2) and melting the glass mat (18), wherein the melting comprises at least one burner (8) directing combustion products into a melting zone under a level (6) of the well-mixed molten glass (4) in the zone, and wherein the routing comprises unwinding the glass mat (18) off of a roll (16) of glass mat using an unwind system (14, 15) and a mechanism (24) selected from the group consisting of a pair of powered nip rolls, a nip compression conveyor, and opposed conveyors compressing the product.
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Abstract
A method for recycling glass mat waste, wound rovings, and other products includes providing a source of glass mat, or a plurality of rovings, for example on a roll, and routing the glass mat or rovings into a submerged combustion melter. An unwind system and a pair of powered nip rolls, powered conveyors, or other arrangement may work in combination to provide a substantially consistent rate of material into the melter. The melter may operate under less than atmospheric pressure to avoid fumes escaping the melter. A slot in the melter allows ingress of the glass mat or rovings into the melter, and a glass mat former such as a folder may be used to ensure that the mat fits through the slot. Alternatively, the glass mat may be cut by a slitter prior to entering the slot.
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Citations
36 Claims
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1. A method of recycling glass mat (18) materials, comprising:
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a) providing a source (16) of glass mat (18), wherein the glass mat (18) is selected from the group consisting of nonwoven and woven materials; b) routing the glass mat (18) at a substantially consistent feed rate into a submerged combustion melter (2) through a slot (26) in the melter (2) and then directly into a well-mixed mass of molten glass (4) within the melter (2) and melting the glass mat (18), wherein the melting comprises at least one burner (8) directing combustion products into a melting zone under a level (6) of the well-mixed molten glass (4) in the zone, and wherein the routing comprises unwinding the glass mat (18) off of a roll (16) of glass mat using an unwind system (14, 15) and a mechanism (24) selected from the group consisting of a pair of powered nip rolls, a nip compression conveyor, and opposed conveyors compressing the product. - View Dependent Claims (2, 3, 4, 5)
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6. A method of recycling glass fiber roving (152) materials, comprising:
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a) providing a source (16) of glass fiber roving (152); b) routing the glass fiber roving (152) at a substantially consistent feed rate into a submerged combustion melter (2) through a slot (26) in the melter (2) and then directly into a well-mixed mass of molten glass (4) within the melter (2) and melting the glass fiber roving (152), wherein the melting comprises at least one burner (8) directing combustion products into a melting zone under a level (6) of the well-mixed molten glass (4) in the zone, and wherein the routing comprises unwinding the glass fiber roving (152) off of a roll (16) glass fiber roving using an unwind system (14, 15) and a mechanism (24) selected from the group consisting of a pair of powered nip rolls, a nip compression conveyor, and opposed conveyors compressing the product. - View Dependent Claims (7)
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8. A method comprising:
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a) providing a source of glass mat on a roll; b) routing the glass mat by unwinding the glass mat from the roll into a submerged combustion melter and melting the glass mat; and c) recovering heat from hot flue gases. - View Dependent Claims (9, 10, 11)
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12. A method of recycling glass mat materials, comprising:
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a) providing a source of glass mat selected from the group consisting of non-woven materials, woven materials, and combinations or mixtures thereof; b) routing the glass mat at a substantially consistent feed rate into a submerged combustion melter through a slot in the melter and then directly into molten glass within the submerged combustion melter and melting the glass mat using one or more submerged combustion burners attached to the submerged combustion melter, wherein the substantially consistent feed rate is accomplished by unwinding the glass mat off of a roll of glass mat using an unwind system and a mechanism selected from the group consisting of a pair of powered nip rolls, a nip compression conveyor, and opposed conveyors compressing the product; and c) wherein heat is recovered from hot flue gases. - View Dependent Claims (13, 14, 15, 16, 17, 18, 19)
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20. A method for producing glass using a submerged combustion melter having an exhaust chute that vents hot flue gases from the submerged combustion melter comprising:
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a) feeding glass precursor raw materials from a roll into the submerged combustion melter; b) melting glass precursor raw materials in the submerged combustion melter using one or more submerged combustion burners attached to the melter; and c) recovering heat from the hot flue gases via a heat exchanger. - View Dependent Claims (21, 22)
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23. A method for producing glass using one or more submerged combustion burners attached to a submerged combustion melter having an exhaust chute that vents hot flue gases from the submerged combustion melter comprising:
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feeding glass precursor raw material through the exhaust chute into the submerged combustion melter, and using heat from the hot flue gases to heat the raw material; and unwinding the raw material from a roll prior to feeding the raw material through the exhaust chute into the submerged combustion melter. - View Dependent Claims (24, 25)
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26. A method for manufacturing a glass product comprising:
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unwinding a roll of non-woven mat and introducing the non-woven mat of glass fibers held together with a binder into a submerged combustion melter and then directly into a well-mixed mass comprising molten glass;
withdrawing at least a portion of the mass comprising molten glass from the submerged combustion melter; andforming the mass comprising molten glass into a solidified glass product. - View Dependent Claims (27, 28, 29, 30)
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31. A method comprising:
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a) providing a source of scrap on a roll; b) routing the scrap by unwinding the roll into a submerged combustion melter and melting the scrap; and c) recovering heat from hot flue gases. - View Dependent Claims (32, 33)
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34. A method comprising:
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a) providing a source of glass mat on a roll; b) routing the glass mat by unwinding the roll at a substantially consistent feed rate into a mass of molten glass in a submerged combustion melter and melting the glass mat using one or more submerged combustion burners attached to the melter; and c) recovering heat from hot flue gases produced by the burners and melting of the glass mat. - View Dependent Claims (35, 36)
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Specification