Computational fluid dynamics modelling of glass melting processes, by Dries HEGEN (TNO)


“For several issues on glass melting processes, like energy consumption, glass quality & defects and production increase, that industry is looking at, CFD modeling is often a key to make steps forward. Therefore, strengths and benefits of CFD modeling are demonstrated for an oxy-fuel E-glass fiber furnace, where the effect of changes in burner settings and furnace design on the evaporation rate of a volatile component have been investigated. This has been done by simulation of the complete furnace, which includes melting tank and combustion space.

The study is carried out by use of the body-fitted multi-physics CFD code GTM-X, developed by TNO Glass Group. Application of body-fitted grids, parallelization and local grid refinement techniques for the multi-physics model calculations with GTM-X reduces the simulation turn-around time significantly. A wide range of glass-dedicated sub-models are available within GTM-X, such as those describing:
Batch melting and conversion, electrical boosting, foam formation, mechanical stirring and forced bubbling
Radiation heat transfer in glass as well as in the combustion space
Turbulence, combustion of gas and oil with air and oxygen, soot formation and oxidation and NOx formation
Evaporation of volatile components from the glass melt, resulting depletion of glass and corrosion of refractory
Redox state of the glass and release of fining gases
Glass quality by the application of an accurate and fast particle trace model, determining:
- Residence time distributions and minimum residence time
- Quality indices for melting, fining, temperature and homogeneity
- Dissolution of sand grains or stones.”

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