| Numerical simulations on float glass melting furnace using China Luoyang float glass technology were done based on the deep analysis of the domestic and foreign glass melting furnace simulation. The aim of this paper is to optimize the structure and improve the efficiency of glass melting furnace. In this paper the characteristics of glass fluids in the melting furnace were studied firstly to increase the glass quality and decrease energy consumption. Then, the optimized float glass melting furnace were brought forward and tested according to the flowing characteristics of glass fluid. Finally, the simulations and the optimizations of correlative assistant facilities were done.The numerical simulation method was adopted with the melting glass fluid in melting furnace as tha main research object. Firstly, a glass fluid model with the daily melting quantities being 500 tons (500 t/d) was established and the simulation results were validated by the detected side stripe images. Secondly, based on the model established above, one boundary condition, i.e., the melting quantity, was changed to investigate its effect on flowing quantities and outflow quantities of glass fluids in the melting furnace. The relationship between glass quality and energy consumption with varied melting quantities was also discussed. Thirdly, the effects of different furnace siege structures and depths of the waist cooler under fluid surface on glass quality and energy consumption were simulated and discussed, respectively. Finally, a glass fluid model employing the waist vertical stirrer was established and the initial velocity boundary conditions were applyed at the waist obtained in the first step. The effect of varied stirring speeds on glass quality was also discussed.ANSYS CFD software was adopted to simulate the flowing of glass fluid in the float glass melting furnace. The YTF—2003 float glass stripe image instrument was adopted to gather the side stripe images which were used to contrast and validate the simulation results.The results showed that there are three glass fluid cycles in the melting furnace and partial glass fluid could flow out of the melting furnace along the circulations to form the different layers of glass. Cycle I exists in front of the hot spot. Partial glass fluids of cycle I directly flow toward the top glass fluid near the furnace outlet and finally form the top glass. Cycle II locates between the hot spot and the furnace outlet where partial glass fluids of cycle II flows toward the place under the glass fluid of cycle I near the furnace outlet and finally forms the middle glass. Cycle III only circles in the working region and partial glass fluids of this cycle flows toward the place under the glass fluid of cycle II near the furnace outlet and finally forms the bottom glass. With the increased daily melting quantities, the homogeneity and the quality of the glass are deteriorated. On the contrary, the unit energy consumption decreases with increasing daily melting quantities., the flowing quantities of cycle II reduce at increasing daily melting quantities, but the flowing quantities of cycle III increase and the outflow quantities of cycle I and cycle III increase. From the viewpoint of energy saving, in models with different siege structure, the greatest energy saving effect of the furnaces siege is that with step siege shapes, followed by that with siege raised before the waist and lastly that with siege raised after the waist form high to low. However, from a viewpoint of glass quality, the glass quality of models with furnaces siege raised before and after the waist are similar. Besides, the glass quality of step furnace siege is worse than the others. In models with different depths of the waist cooler under the fluid surface, the optimum depth of the waist cooler is 0.2 m. At different rotate speed of the waist stirrer, the optimum rotate speed of the stirrer is 9 rpm. |
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