Simulation and control of continuous glass melting by microwave heating in a single-mode cavity with energy efficiency optimization

Calculations of continuous glass melting in a single-mode 2.45 GHz microwave oven are reported. The aim of this work is to optimize the microwave heating of the glass raw material to have a controlled and highly efficient oven. The two-way coupling process between electromagnetic and thermal fields is solved using COMSOL software in a 3D transient simulation that includes phase change and surface-to-surface thermal radiation. A methodology was developed and coded to automatically control the microwave energy supply and to maximize the material's microwave absorption during the 3D transient simulation. The developed methodology to achieve high Key Performance Indicators (KPI) was applied to the continuous melting of a glass raw material powder, the results show promising energy consumption reduction and improved task efficiency.