Modeling batch melting: Roles of heat transfer and reaction kinetics

Pokorný, Richard; Hrma, Pavel; Lee, Seungmin; Klouzek, Jaroslav; Choudhary, Manoj K.; Kruger, Albert A.

doi:10.1111/jace.16898

Title: Modeling batch melting: Roles of heat transfer and reaction kinetics

Abstract

Abstract Development of mathematical models of heat and mass transfer in glass‐melting furnaces began in the 1970s and progressed rapidly with advances in sophisticated experimental/numerical techniques and increasing computational power. Today, practically all newly built or rebuilt furnaces are optimized with these models to meet stringent quality requirements, reduce the unit costs of manufacturing, or control emissions. One remaining hurdle is to model the batch‐to‐glass conversion accurately enough to reliably assess the glass production rate. This article summarizes two key aspects of the batch‐conversion modeling—the heat transfer and the kinetics of conversion—and reviews the current state‐of‐the‐art approaches to simulating them. We critically examine the advantages of the commonly used heat transfer approach, but also explain that its predictive capabilities are significantly restricted by the dependence of batch thermal properties on the time‐temperature history. We argue that kinetic approaches to the batch‐conversion modeling would offer a significant improvement when coupled with the heat transfer approach. Finally, we summarize key areas requiring further research on the way toward a realistic model of the batch blanket.

Authors:

^[1]; Hrma, Pavel ^[2];

^[2];

^[1];

^[3]; Kruger, Albert A. ^[4]

Laboratory of Inorganic Materials University of Chemistry and Technology Prague Prague Czech Republic, Institute of Rock Structure and Mechanics of the ASCR v.v.i. Prague Czech Republic
Pacific Northwest National Laboratory Richland WA USA
The Ohio State University Columbus OH USA
U.S. Department of Energy Office of River Protection Richland WA USA

Publication Date:: Thu Nov 28 00:00:00 EST 2019

Sponsoring Org.:: USDOE

OSTI Identifier:: 1576628

Resource Type:: Publisher's Accepted Manuscript

Journal Name:: Journal of the American Ceramic Society

Additional Journal Information:: Journal Name: Journal of the American Ceramic Society Journal Volume: 103 Journal Issue: 2; Journal ID: ISSN 0002-7820

Publisher:: Wiley-Blackwell

Country of Publication:: United States

Language:: English

Citation Formats


                    Pokorný, Richard, Hrma, Pavel, Lee, Seungmin, Klouzek, Jaroslav, Choudhary, Manoj K., and Kruger, Albert A. Modeling batch melting: Roles of heat transfer and reaction kinetics.  United States: N. p., 2019. 
Web.  doi:10.1111/jace.16898.

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                    Pokorný, Richard, Hrma, Pavel, Lee, Seungmin, Klouzek, Jaroslav, Choudhary, Manoj K., & Kruger, Albert A. Modeling batch melting: Roles of heat transfer and reaction kinetics.  United States.  https://doi.org/10.1111/jace.16898

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                    Pokorný, Richard, Hrma, Pavel, Lee, Seungmin, Klouzek, Jaroslav, Choudhary, Manoj K., and Kruger, Albert A. Thu .  
"Modeling batch melting: Roles of heat transfer and reaction kinetics".  United States.  https://doi.org/10.1111/jace.16898.

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@article{osti_1576628,

  title        = {Modeling batch melting: Roles of heat transfer and reaction kinetics},

  author       = {Pokorný, Richard and Hrma, Pavel and Lee, Seungmin and Klouzek, Jaroslav and Choudhary, Manoj K. and Kruger, Albert A.},

  abstractNote = {Abstract Development of mathematical models of heat and mass transfer in glass‐melting furnaces began in the 1970s and progressed rapidly with advances in sophisticated experimental/numerical techniques and increasing computational power. Today, practically all newly built or rebuilt furnaces are optimized with these models to meet stringent quality requirements, reduce the unit costs of manufacturing, or control emissions. One remaining hurdle is to model the batch‐to‐glass conversion accurately enough to reliably assess the glass production rate. This article summarizes two key aspects of the batch‐conversion modeling—the heat transfer and the kinetics of conversion—and reviews the current state‐of‐the‐art approaches to simulating them. We critically examine the advantages of the commonly used heat transfer approach, but also explain that its predictive capabilities are significantly restricted by the dependence of batch thermal properties on the time‐temperature history. We argue that kinetic approaches to the batch‐conversion modeling would offer a significant improvement when coupled with the heat transfer approach. Finally, we summarize key areas requiring further research on the way toward a realistic model of the batch blanket.},

  doi          = {10.1111/jace.16898},

  journal      = {Journal of the American Ceramic Society},

  number       = 2,

  volume       = 103,

  place        = {United States},

  year         = {Thu Nov 28 00:00:00 EST 2019},

  month        = {Thu Nov 28 00:00:00 EST 2019}

}

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Effects of particle size and briquetting of soda-lime-silicate glass batch on viscosity during batch-to-melt conversion

Journal Article Doi, Yoji ; Yano, Tetsuji ; McCarthy, Benjamin P. ; ... - International Journal of Applied Glass Science

To assess the effects of grain size and briquetting on glass-batch melting, we measured the viscosity (?b) of an industrial glass batch during its conversion to molten simulated architectural glass within the temperature interval of 1050 °C to 1300 °C and at a shear rate of 0.02 s-1. On the basis of the mass fraction of undissolved sand (xs), which was determined using X-ray diffraction analysis on quenched batch samples, and the gas-phase fraction (p), which was obtained from volumetric measurements, we established the relationship ln(?b/?m) = a0 + bsxs + app, where ?m is the transition melt viscosity, a0more »« less
https://doi.org/10.1111/ijag.12665

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Title: Modeling batch melting: Roles of heat transfer and reaction kinetics

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Conversion of batch to molten glass, II: Dissolution of quartz particles journal, February 2011

Melting and Fining book, January 2002

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Recent Advances in Mathematical Modeling of Flow and Heat Transfer Phenomena in Glass Furnaces journal, May 2002

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Control of Radioactive Waste Glass Melters: II, Residence Time and Melt Rate Limitations journal, October 1990

Predictions of effective physical properties of complex multiphase materials journal, December 2008

Thermal diffusivity of soda–lime–silica powder batch and briquettes journal, June 2018

Determination of Heat Conductivity and Thermal Diffusivity of Waste Glass Melter Feed: Extension to High Temperatures journal, May 2014

Temperature Distribution within a Cold Cap during Nuclear Waste Vitrification journal, June 2015

Heat transfer from glass melt to cold cap: Gas evolution and foaming journal, April 2019

Cluster formation of silica particles in glass batches during melting journal, June 2010

Effect of glass composition on activation energy of viscosity in glass-melting-temperature range journal, August 2012

Melting of glass batch: Model for multiple overlapping gas-evolving reactions journal, August 2012

Gas Release and Foam Formation During Melting and Fining of Glass journal, January 2006

Model for a steady state foam blanket journal, January 1990

Effect of feed melting, temperature history, and minor component addition on spinel crystallization in high-level waste glass journal, August 2001

Evaluation of Foaming Behavior of Glass Melts by High-Temperature Microscopy journal, March 2016

A simplified mathematical model of glass melt convection in a cold crucible induction melter journal, October 2012

Decay of standing foams: drainage, coalescence and collapse journal, July 1997

Mathematical model of glass tank furnace with batch melting process journal, May 1980

Numerical simulation and experimental analysis of an industrial glass melting furnace journal, April 2008

Effects of heating rate, quartz particle size, viscosity, and form of glass additives on high‐level waste melter feed volume expansion journal, October 2016

Kinetics of Phase Change. I General Theory journal, December 1939

Physicochemical approach to the theory of foam drainage journal, January 2002

Kinetics of growth of spinel crystals in a borosilicate glass journal, July 2002

Radiation Characteristics of Glass Foams journal, November 2000

One‐Dimensional Cold Cap Model for Melters with Bubblers journal, July 2015

Dissolution of Polydisperse Silica Grains in Glass Melts-Analysis journal, October 1990

Mathematical modeling of cold cap journal, October 2012

Predicting the Spinel?Nepheline Liquidus for Application to Nuclear Waste Glass Processing. Part I: Primary Phase Analysis, Liquidus Measurment, and Quasicrystalline Approach journal, June 2007

Numerical Model of Polydispersed Silica Grain Dissolution in Glass Melting Furnaces journal, July 1994

X‐ray tomography of feed‐to‐glass transition of simulated borosilicate waste glasses journal, May 2017

Effect of alkali phosphate content on foaming of CRT panel glass using Mn3O4 and carbon as foaming agents journal, February 2018

A methodology to reduce the computational cost of transient multiphysics simulations for waste vitrification journal, July 2018

Foaming during nuclear waste melter feeds conversion to glass: Application of evolved gas analysis journal, April 2018

Use of computer flow dynamics in glass technology journal, October 2004

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Effects of particle size and briquetting of soda-lime-silicate glass batch on viscosity during batch-to-melt conversion journal, September 2018

Heat transfer from glass melt to cold cap: Melting rate correlation equation journal, September 2018

Effect of bubble size distribution on the enrichment and collapse in foams journal, July 1986

Foaming in Glass Melts Produced by Sodium Sulfate Decomposition under Isothermal Conditions journal, March 1991

Determination of Temperature-Dependent Heat Conductivity and Thermal Diffusivity of Waste Glass Melter Feed journal, May 2013

Cold-cap reactions in vitrification of nuclear waste glass: Experiments and modeling journal, May 2013

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Effect of heating rate on glass foaming: Transition to bulk foam journal, February 2009

Foaming in Glass Melts Produced by Sodium Sulfate Decomposition under Ramp Heating Conditions journal, November 1992

Dissolution retardation of solid silica during glass-batch melting journal, July 2011

Glass production rate in electric furnaces for radioactive waste vitrification journal, April 2019

Reaction of soda–lime–silica glass melt with water vapour at melting temperatures journal, May 2015

Development of a Validation Approach for an Integrated Waste Glass Melter Model journal, April 2018

Kinetics of Phase Change. II Transformation‐Time Relations for Random Distribution of Nuclei journal, February 1940

Radiation Characteristics of Glass Containing Gas Bubbles journal, August 2003

Dissolution and growth of spinel crystals in a borosilicate glass journal, October 2002

The Effect of Temperature on the Redox Constraints for the Processing of High-Level Nuclear Waste into a Glass Waste Form journal, January 1989

X-Ray Tomography Imaging of Porous Polyolefin Particles in an Electron Microscope journal, May 2013

Radiative heat transfer in processing of glass-forming melts journal, August 2017

Interaction between solid, liquid and gas during glass batch melting journal, July 1986

Determination of heat conductivity of waste glass feed and its applicability for modeling the batch-to-glass conversion journal, July 2017

Reaction Kinetics in Differential Thermal Analysis journal, November 1957

Glass foams: formation, transport properties, and heat, mass, and radiation transfer journal, November 2002

Effect of melter feed foaming on heat flux to the cold cap journal, December 2017

Modeling of heat transfer in the melting of a glass batch journal, March 1986

A model for unsteady state drainage of a static foam journal, January 1991

Determination of reaction kinetics during vitrification of radioactive liquid waste for different types of base glass journal, June 2019

Stability of vertical films of molten glass due to evaporation journal, August 2012

Dependence of Reaction Velocity upon surface and Agitation journal, August 1931

A model for foam formation, stability, and breakdown in glass-melting furnaces journal, March 2006

In situ measurements of reactions in a glass-forming batch by X-ray and neutron diffraction journal, August 2018

Bubble removal and sand dissolution in an electrically heated glass melting channel with defined melt flow examined by mathematical modelling journal, January 2017

Simulink model of an iductive MHD generator journal, January 2017

Thermal Conductivity: VIII, A Theory of Thermal Conductivity of Porous Materials journal, February 1954

Predicting the Spinel?Nepheline Liquidus for Application to Nuclear Waste Glass Processing. Part II: Quasicrystalline Freezing Point Depression Model
journal, June 2007

Conversion of batch to molten glass, II: Dissolution of quartz particles
journal, February 2011

Melting and Fining
book, January 2002

Kinetic model for quartz and spinel dissolution during melting of high-level-waste glass batch
journal, November 2013

Recent Advances in Mathematical Modeling of Flow and Heat Transfer Phenomena in Glass Furnaces
journal, May 2002

Glass Science in the United States: Current Status and Future Directions
journal, January 2014

Multiphase approach to coupled conduction–radiation heat transfer in reconstructed polymeric foams
journal, September 2014

Heat transfer from glass melt to cold cap: Effect of heating rate
journal, February 2019

Low-Reynolds-number rising of a bubble near a free surface at vanishing Bond number
journal, June 2016

Control of Radioactive Waste Glass Melters: II, Residence Time and Melt Rate Limitations
journal, October 1990

Predictions of effective physical properties of complex multiphase materials
journal, December 2008

Thermal diffusivity of soda–lime–silica powder batch and briquettes
journal, June 2018

Determination of Heat Conductivity and Thermal Diffusivity of Waste Glass Melter Feed: Extension to High Temperatures
journal, May 2014

Temperature Distribution within a Cold Cap during Nuclear Waste Vitrification
journal, June 2015

Heat transfer from glass melt to cold cap: Gas evolution and foaming
journal, April 2019

Cluster formation of silica particles in glass batches during melting
journal, June 2010

Effect of glass composition on activation energy of viscosity in glass-melting-temperature range
journal, August 2012

Melting of glass batch: Model for multiple overlapping gas-evolving reactions
journal, August 2012

Gas Release and Foam Formation During Melting and Fining of Glass
journal, January 2006

Model for a steady state foam blanket
journal, January 1990

Effect of feed melting, temperature history, and minor component addition on spinel crystallization in high-level waste glass
journal, August 2001

Evaluation of Foaming Behavior of Glass Melts by High-Temperature Microscopy
journal, March 2016

A simplified mathematical model of glass melt convection in a cold crucible induction melter
journal, October 2012

Decay of standing foams: drainage, coalescence and collapse
journal, July 1997

Mathematical model of glass tank furnace with batch melting process
journal, May 1980

Numerical simulation and experimental analysis of an industrial glass melting furnace
journal, April 2008

Effects of heating rate, quartz particle size, viscosity, and form of glass additives on high‐level waste melter feed volume expansion
journal, October 2016

Kinetics of Phase Change. I General Theory
journal, December 1939

Physicochemical approach to the theory of foam drainage
journal, January 2002

Kinetics of growth of spinel crystals in a borosilicate glass
journal, July 2002

Radiation Characteristics of Glass Foams
journal, November 2000

One‐Dimensional Cold Cap Model for Melters with Bubblers
journal, July 2015

Dissolution of Polydisperse Silica Grains in Glass Melts-Analysis
journal, October 1990

Mathematical modeling of cold cap
journal, October 2012

Predicting the Spinel?Nepheline Liquidus for Application to Nuclear Waste Glass Processing. Part I: Primary Phase Analysis, Liquidus Measurment, and Quasicrystalline Approach
journal, June 2007

Numerical Model of Polydispersed Silica Grain Dissolution in Glass Melting Furnaces
journal, July 1994

X‐ray tomography of feed‐to‐glass transition of simulated borosilicate waste glasses
journal, May 2017

Effect of alkali phosphate content on foaming of CRT panel glass using Mn3O4 and carbon as foaming agents
journal, February 2018

A methodology to reduce the computational cost of transient multiphysics simulations for waste vitrification
journal, July 2018

Foaming during nuclear waste melter feeds conversion to glass: Application of evolved gas analysis
journal, April 2018

Use of computer flow dynamics in glass technology
journal, October 2004

Effect of furnace atmosphere on E-glass foaming
journal, December 2006

Effects of particle size and briquetting of soda-lime-silicate glass batch on viscosity during batch-to-melt conversion
journal, September 2018

Heat transfer from glass melt to cold cap: Melting rate correlation equation
journal, September 2018

Effect of bubble size distribution on the enrichment and collapse in foams
journal, July 1986

Foaming in Glass Melts Produced by Sodium Sulfate Decomposition under Isothermal Conditions
journal, March 1991

Determination of Temperature-Dependent Heat Conductivity and Thermal Diffusivity of Waste Glass Melter Feed
journal, May 2013

Cold-cap reactions in vitrification of nuclear waste glass: Experiments and modeling
journal, May 2013

Mathematical modelling of sand dissolution in a glass melting channel with controlled glass flow
journal, May 2012

Mathematical Modeling of Flow and Heat Transfer Phenomena in Glass Melting, Delivery, and Forming Processes: Mathematical Modeling of Glass Melting, Delivery, and Forming Processes
journal, May 2010

Effect of heating rate on glass foaming: Transition to bulk foam
journal, February 2009

Foaming in Glass Melts Produced by Sodium Sulfate Decomposition under Ramp Heating Conditions
journal, November 1992

Dissolution retardation of solid silica during glass-batch melting
journal, July 2011

Glass production rate in electric furnaces for radioactive waste vitrification
journal, April 2019

Reaction of soda–lime–silica glass melt with water vapour at melting temperatures
journal, May 2015

Development of a Validation Approach for an Integrated Waste Glass Melter Model
journal, April 2018

Kinetics of Phase Change. II Transformation‐Time Relations for Random Distribution of Nuclei
journal, February 1940

Radiation Characteristics of Glass Containing Gas Bubbles
journal, August 2003

Dissolution and growth of spinel crystals in a borosilicate glass
journal, October 2002

The Effect of Temperature on the Redox Constraints for the Processing of High-Level Nuclear Waste into a Glass Waste Form
journal, January 1989

X-Ray Tomography Imaging of Porous Polyolefin Particles in an Electron Microscope
journal, May 2013

Radiative heat transfer in processing of glass-forming melts
journal, August 2017

Interaction between solid, liquid and gas during glass batch melting
journal, July 1986

Determination of heat conductivity of waste glass feed and its applicability for modeling the batch-to-glass conversion
journal, July 2017

Reaction Kinetics in Differential Thermal Analysis
journal, November 1957

Glass foams: formation, transport properties, and heat, mass, and radiation transfer
journal, November 2002

Effect of melter feed foaming on heat flux to the cold cap
journal, December 2017

Modeling of heat transfer in the melting of a glass batch
journal, March 1986

A model for unsteady state drainage of a static foam
journal, January 1991

Determination of reaction kinetics during vitrification of radioactive liquid waste for different types of base glass
journal, June 2019

Stability of vertical films of molten glass due to evaporation
journal, August 2012

Dependence of Reaction Velocity upon surface and Agitation
journal, August 1931

A model for foam formation, stability, and breakdown in glass-melting furnaces
journal, March 2006

In situ measurements of reactions in a glass-forming batch by X-ray and neutron diffraction
journal, August 2018

Bubble removal and sand dissolution in an electrically heated glass melting channel with defined melt flow examined by mathematical modelling
journal, January 2017

Simulink model of an iductive MHD generator
journal, January 2017

Thermal Conductivity: VIII, A Theory of Thermal Conductivity of Porous Materials
journal, February 1954