Modelling of the controlled melt flow in a glass melting space — Its melting performance and heat losses

• Helical-like melt flow was examined in a model melting space as potentially efficient.
• The conditions of its setting were defined and realized by mathematical modelling.
• The sand dissolution, bubble removal, and space utilization were followed.
• The substantial improvement of glass melting characteristics was achieved.
• The application of controlled melt flow in glass melting practice was discussed.

The factors influencing the character of the melt flow were defined and examined in a model glass melting space. The batch blanket was simulated by an inflowing glass melt with sand particles and bubbles and the heating elements by the defined volumes of the melt where heat was evolved. The character of the melt flow was set up by a proper arrangement of the heating elements in the space. The sand dissolution and the bubble removal were modelled in the space; the space utilization, melting performance, and heat losses were calculated. The required character of the melt flow was brought about by the energy evolution in the region of the longitudinal space axis and by the supply of a substantial part of energy to the region beneath the inflowing melt. The results of the modelling have confirmed that the suitable flow character in the space was a helical-like flow, which was attained by the combination of an almost uniform forward flow with imposed transversal melt circulations. High values of the space utilization, several times higher melting performance and proportionally lower specific heat losses were acquired when compared with the values attained under conditions simulating the melt flow in industrial melting furnaces.