Integrated Modeling Analysis of Glass Furnace Forehearths as Applied to Production Planning Optimization

Abstract

A two-dimensional model was developed to investigate thermal variations within a glass furnace forehearth as used in the production of glass fibers. The goal of the simulations was to develop a production planning tool that can be used not only to help establish product changeover guidelines but also to identify undesirable processing conditions. Commercially available software, FLUENT and FIDAP, were utilized as the finite element computational fluid dynamic (CFD) solvers. The models incorporated sufficient detail to investigate primary production control parameters for various types, configurations, and geometries of forehearths as used throughout the industry. The models incorporated various throughput rates as represented by different fiber forming bushings and processing parameters. In addition, the height of the glass surface was computed and integrated into the molten glass flow and heat transfer equations.

Steady-state and transient forehearth simulations were conducted and the results were compared with previously published forehearth experimental operating data. The simulations illustrated that a bushing changeover has a significant impact on the glass temperature and flow in the forehearth, whereas variations of glass height were shown to have a minimal effect. The models developed in this thesis are adaptable to other bushing configurations and the models should provide useful product changeover guidance for the purpose of optimizing production planning.