Processes for producing molten glasses from glass batches using turbulent submerged combustion melting, and systems for carrying out such processes

Abstract

Processes and systems for producing molten glass using submerged combustion melters, including densifying an initial composition comprising vitrifiable particulate solids and interstitial gas to form a densified composition comprising the solids by removing a portion of the interstitial gas from the composition. The initial composition is passed from an initial environment having a first pressure through a second environment having a second pressure higher than the first pressure to form a composition being densified. Any fugitive particulate solids escaping from the composition being densified are captured and recombined with the composition being densified to form the densified composition. The densified composition is fed into a feed inlet of a turbulent melting zone of a melter vessel and converted into turbulent molten material using at least one submerged combustion burner in the turbulent melting zone.

What is claimed is: 
     
         1 . A method of introducing a substantially solid form of a glass-forming material into a submerged combustion melter with a feeder system, the method comprising:
 providing the submerged combustion melter, wherein the submerged combustion melter comprises a melt chamber comprising a floor, a roof, and a least one wall, wherein the floor, the roof, and the at least one wall at least partially define an interior of the melt chamber;   disposing the feeder system proximate the at least one wall of the melt chamber;   receiving the substantially solid form of the glass-forming material in a feed chamber of the feeder system, wherein the substantially solid form of the glass-forming material comprises an initial portion of the substantially solid form of the glass-forming material and a subsequent portion of the substantially solid form of the glass-forming material;   advancing the initial portion of the substantially solid form of the glass-forming material from the feed chamber, wherein the initial portion of the substantially solid form of the glass-forming material is advanced with a screw feeder at least partially disposed in the feed chamber, wherein advancing the initial portion of the substantially solid form of the glass-forming material simultaneously compresses the initial portion of the substantially solid form of the glass-forming material into an initial compressed portion of the substantially solid form of the glass-forming material;   conveying the initial compressed portion of the substantially solid form of the glass-forming material into a seal section disposed at an end of the screw feeder, wherein the seal section is sealed from the submerged combustion melter via at least the initial compressed portion of the substantially solid form of the glass-forming material;   advancing the subsequent portion of the substantially solid form of the glass-forming material from the feed chamber, wherein the subsequent portion of the substantially solid form of the glass-forming material is advanced with the screw feeder, wherein advancing the subsequent portion of the substantially solid form of the glass-forming material simultaneously compresses the subsequent portion of the substantially solid form of the glass-forming material into a subsequent compressed portion of the substantially solid form of the glass-forming material;   conveying the subsequent compressed portion of the substantially solid form of the glass-forming material into the seal section; and   releasing the initial compressed portion of the substantially solid form of the glass-forming material from the seal section and into the interior of the melt chamber.   
     
     
         2 . The method of  claim 1 , wherein the interior of the melt chamber is configured to contain therein the turbulent melt form of the glass-forming material, wherein the turbulent melt form has an upper surface, wherein the first compressed portion of the substantially solid form of the glass-forming material is released into the interior of the melt chamber above the upper surface. 
     
     
         3 . The method of  claim 1 , wherein releasing the first compressed portion of the substantially solid form of the glass-forming material from the seal section comprises actuating a ram. 
     
     
         4 . The method of  claim 1 , wherein releasing the first compressed portion of the substantially solid form of the glass-forming material is performed after conveying the initial compressed portion of the substantially solid form of the glass-forming material into the seal section and before conveying the subsequent compressed portion of the substantially solid form of the glass-forming material into the seal section. 
     
     
         5 . The method of  claim 1 , wherein advancing the initial portion of the substantially solid form of the glass-forming material comprises advancing the initial portion of the substantially solid form of the glass-forming material in a substantially horizontal direction. 
     
     
         6 . The method of  claim 1 , wherein advancing the initial portion of the substantially solid form of the glass-forming material comprises advancing the initial portion of the substantially solid form of the glass-forming material in a first direction; and wherein releasing the first compressed portion of the substantially solid form of the glass-forming material from the seal section introduces the first compressed portion of the substantially solid form of the glass-forming material to the interior of the melt chamber in a second direction different than the first direction. 
     
     
         7 . The method of  claim 4 , wherein disposing the feeder system comprises connecting at least a portion of the feeder system proximate at least one of the wall and the roof. 
     
     
         8 . The method of  claim 2 , wherein the seal section comprises a high pressure shroud to substantially contain the initial compressed portion of the substantially solid form of the glass-forming material from the seal section and the subsequent compressed portion of the substantially solid form of the glass-forming material in the seal section. 
     
     
         9 . The method of  claim 8 , wherein advancing the initial portion of the substantially solid form of the glass-forming material from the feed chamber comprises advancing the initial compressed portion of the substantially solid form of the glass-forming material towards the high pressure shroud. 
     
     
         10 . The method of  claim 9 , wherein the screw feeder extends into the high pressure shroud. 
     
     
         11 . A method of melting, with a submerged combustion melter system, a compressed portion of a substantially solid form of a glass-forming material into a turbulent melt form of the glass-forming material, the method comprising:
 providing the submerged combustion melter system, wherein the submerged combustion melter system comprises a melt chamber at least partially defined by a floor, a roof, and a least one wall, wherein the floor, the roof, and the at least one wall at least partially define an interior of the melt chamber;   disposing the feed system proximate the at least one wall of the melt chamber;   receiving the substantially solid form of the glass-forming material in a feed chamber of the feed system, wherein the substantially solid form of the glass-forming material comprises an initial portion of the substantially solid form of the glass-forming material and a subsequent portion of the substantially solid form of the glass-forming material;   advancing the initial portion of the substantially solid form of the glass-forming material from the feed chamber, wherein the initial portion of the substantially solid form of the glass-forming material is advanced with a screw feeder at least partially disposed in the feed chamber, wherein advancing the initial portion of the substantially solid form of the glass-forming material simultaneously compresses the initial portion of the substantially solid form of the glass-forming material into an initial compressed portion of the substantially solid form of the glass-forming material;   conveying the initial compressed portion of the substantially solid form of the glass-forming material into a seal section disposed at an end of the screw feeder, wherein the seal section is sealed from the submerged combustion melter via at least the initial compressed portion of the substantially solid form of the glass-forming material;   releasing the initial compressed portion of the substantially solid form of the glass-forming material from the seal section and into the interior of the melt chamber; and   melting into the turbulent melt form of the glass-forming material, with a submerged combustion burner in communication with the interior of the melt chamber, the first compressed portion of the substantially solid form of the glass-forming material.   
     
     
         12 . The method of  claim 11 , wherein the seal section is disposed above an upper portion of the turbulent melt form of the glass-forming material in the interior of the melt chamber. 
     
     
         13 . The method of  claim 12 , further comprising:
 advancing the subsequent portion of the substantially solid form of the glass-forming material from the feed chamber, wherein the subsequent portion of the substantially solid form of the glass-forming material is advanced with the screw feeder, wherein advancing the subsequent portion of the substantially solid form of the glass-forming material simultaneously compresses the subsequent portion of the substantially solid form of the glass-forming material into a subsequent compressed portion of the substantially solid form of the glass-forming material;   conveying the subsequent compressed portion of the substantially solid form of the glass-forming material into the seal section; and   releasing the subsequent compressed portion of the substantially solid form of the glass-forming material from the seal section and into the interior of the melt chamber.   
     
     
         14 . The method of  claim 13 , wherein releasing the initial compressed portion of the substantially solid form of the glass-forming material is performed after conveying the initial compressed portion of the substantially solid form of the glass-forming material into the seal section and before conveying the subsequent compressed portion of the substantially solid form of the glass-forming material into the seal section. 
     
     
         15 . The method of  claim 11 , wherein disposing the feeder system comprises connecting at least a portion of the feed system to a location proximate at least one of the wall and the roof. 
     
     
         16 . The method of  claim 11 , wherein disposing the feed system comprises connecting an outlet of the feed system to at least one of the wall and the roof. 
     
     
         17 . The method of  claim 11 , wherein the seal section comprises a high pressure shroud to substantially contain the initial compressed portion of the substantially solid form of the glass-forming material and the subsequent compressed portion of the substantially solid form of the glass-forming material. 
     
     
         18 . The method of  claim 11 , wherein the screw feeder extends into the high pressure shroud. 
     
     
         19 . A submerged combustion melter system for melting a glass-forming material from a substantially solid form into a turbulent melt form, the submerged combustion melter system comprising:
 a melt chamber comprising a floor, a roof, and a least one wall, wherein the floor, the roof, and the at least one wall at least partially define an interior of the melt chamber, and wherein the interior of the melt chamber is configured to receive the substantially solid form of the glass-forming material, and contain the turbulent melt form of the glass-forming material, wherein the turbulent melt form of the glass-forming material has a turbulent melt surface, and wherein the floor defines a burner opening;   at least one submerged combustion burner disposed in the burner opening;   a feed system disposed proximate the at least one wall, wherein the feed system is configured to feed to the interior of the melt chamber the substantially solid form of the glass-forming material, and wherein the feed system comprises:
 a source chamber configured to receive the substantially solid form of the glass-forming material; 
 a shroud communicatively coupled to the source chamber; 
 a screw feeder rotatably disposed in the shroud, the screw feeder comprising a shaft and a thread, wherein rotation of the screw feeder compresses the substantially solid form of the glass-forming material; 
 a seal section disposed at a first end of the shroud, wherein the seal section is configured to receive the compressed substantially solid form of the glass-forming material from the screw feeder; and 
 a ram disposed proximate the seal section, wherein actuation of the ram releases the compressed substantially solid form of the glass-forming material from the seal section via an outlet and into the interior of the melt chamber. 
   
     
     
         20 . The submerged combustion melter system of  claim 19 , wherein the outlet is disposed above the turbulent melt surface. 
     
     
         21 . The submerged combustion melter system of  claim 19 , wherein the thread comprises a variable pitch along the shaft. 
     
     
         22 . The submerged combustion melter system of  claim 19 , wherein the outlet, the seal section, and the shroud are arranged so as to prevent ingress of the turbulent melt form of the glass-forming material. 
     
     
         23 . The submerged combustion melter system of  claim 19 , wherein the screw feeder is disposed substantially horizontally. 
     
     
         24 . The submerged combustion melter system of  claim 19 , wherein the screw feeder comprises a first end disposed proximate the source chamber and a second end disposed proximate the seal section. 
     
     
         25 . The submerged combustion melter system of  claim 19 , further comprising an actuatable element operatively connected to the ram, wherein actuation of the ram causes a corresponding actuation of the actuatable element. 
     
     
         26 . The submerged combustion melter system of  claim 25 , wherein the corresponding actuation of the actuatable element opens the seal section. 
     
     
         27 . The submerged combustion melter system of  claim 19 , wherein the shroud comprises walls configured to resist deformation caused by compaction of the substantially solid form of the glass-forming material. 
     
     
         28 . A submerged combustion melter system for melting a glass-forming material from a substantially solid form into a turbulent melt form, the submerged combustion melter system comprising:
 a melt chamber comprising a floor, a roof, and a least one wall, wherein the floor, the roof, and the at least one wall at least partially define an interior of the melt chamber, and wherein the interior of the melt chamber is configured to receive the substantially solid form of the glass-forming material, and contain the turbulent melt form of the glass-forming material, wherein the turbulent melt form of the glass-forming material has a turbulent melt surface, and wherein the floor defines a burner opening;   at least one submerged combustion burner disposed in the burner opening;   a feed system disposed proximate the at least one wall, wherein the feed system is configured to feed to the interior of the melt chamber the substantially solid form of the glass-forming material, and wherein the feed system comprises:
 a source chamber configured to receive the substantially solid form of the glass-forming material; 
 a first pressurizing zone for compressing the substantially solid form of the glass-forming material into a first compressed substantially solid form of the glass-forming material; 
 a pressure shroud disposed proximate an outlet of the first pressurizing zone, wherein the pressure shroud at least partially defines a second pressurizing zone configured to receive the first compressed substantially solid form of the glass-forming material; and 
 a release system disposed at an end of the pressure shroud, wherein the release system comprises an actuator for releasing, from the pressure shroud, the first compressed substantially solid form of the glass-forming material. 
   
     
     
         29 . The submerged combustion melter system of  claim 28 , wherein the first pressurizing zone comprises a first screw feeder. 
     
     
         30 . The submerged combustion melter system of  claim 29 , wherein the second pressurizing zone comprises a second screw feeder.