Abstract: A method and assembly is provided for modifying a regenerative or a recuperative furnace system having air-fuel burners for use with synthetic air. A portion of the exhaust gases from the furnace is recycled and mixed with oxygen gas to form synthetic air. The synthetic air is then used to support combustion in the furnace. A cassette regenerative oxy-fuel cross-fired furnace system is also provided. The cassette regenerative furnace system utilizes synthetic air containing a mixture of recycled exhaust gases and oxygen in combination with cassette regenerators.

Abstract: A cassette regeneration system (10) for an oxy-fuel regeneration assembly (52) having oxy-fuel burners (54) includes a first regeneration assembly (62) having at least one removably connected cassette regenerator (32), a second regeneration assembly (62') having at least one removably connected cassette regenerator and an exhaust reversal valve assembly (82) in flow communication with the first and second regeneration assemblies and configured to selectively direct exhaust gas from the furnace to a selected one of the first and second regeneration assemblies. The system further includes an air supply conduit (98), at least one preheated air conduit (102) and an air reversal valve assembly (80) in flow communication with the air supply conduit and the at least one preheated air conduit and configured to selectively direct air from the air supply air conduit to a selected one of the first and second regeneration assemblies to the at least one preheated air conduit.

Abstract: An apparatus and method for the preferably continuous manufacture of foamed material using a furnace are provided. A two-part mold mechanism is provided that includes an upper portion and a lower portion that are each endless loops and cooperate with one another to form a closed mold within the furnace. The upper and lower portions can each comprise a plurality of transverse mold members that can be easily replaced or exchanged during operation of the apparatus. A feed mechanism is provided for introducing material that is to be foamed to the mold mechanism upstream of the furnace. Scrapers or the like can be provided downstream of the furnace to aid in separating and supporting foamed material from the mold mechanism.

Abstract: A method and apparatus for the production of colored glass includes the steps of diverting a stream of clear molten glass from at least one glass melting furnace through one or more transport channels to a color treatment chamber. Recycled cullet and color additive are added to a charging end of the treatment chamber. The treatment chamber is heated to melt the cullet and further heat the remaining feedstock to form a molten bath of colored glass which is thermally and chemically homogenized in the treatment chamber. Refractory rotary paddle wheels positioned in the transport channels regulate the flow rate and level of the molten glass and provide for selective shut off of individual glass streams.

Abstract: Electrode blocks and multiple-piece assemblies are provided for electric, glass-melting furnaces to reduce the occurrence and extent of cracking which occurs in monolithic electrode blocks from thermal stresses induced by a high temperature gradient between such blocks or the block assembly and a fluid-cooled electrode and from thermal shock encountered in repositioning the electrode. An insert block of a high thermal stress and glass corrosion/erosion resistant refractory material is configured to receive an electrode assembly. A holder block, which may be of the same material or another material, including a material having less thermal stress strength or less glass corrosion/erosion resistance than the insert block material, has a passageway therethrough to receive at least part of the insert block with electrode assembly therethrough.

Abstract: A charger apparatus having a reciprocable charger plate for feeding batch and cullet to a glass melting furnace. The cullet is preferably first preheated in a charger mounted cullet feed hopper utilizing exhaust gas from the furnace as the heat source. The cullet feed hopper deposits a layer of preheated cullet over a layer of batch material on the charger plate prior to delivery to the furnace so as to reduce steam generation and dusting problems. The charger also includes a primary cullet hopper in which cold cullet is preheated with off-gas from the preheater of the cullet feed hopper for subsequent delivery to the cullet feed hopper. The charger may also include an under plate pusher which is tiltable about a vertical axis to provide improved melt control and to direct the charge away from the furnace sidewall so as to improve refractory life. Dusting and carry over of fines in the exhaust gas is minimized due to the use of pre-melt electrodes in the charging zone.

Abstract: An advanceable refractory ceramic electrode is provided for use in the electrical heating of a molten mass in a furnace. The electrode has a tubular ceramic body having a terminal region that in use is immersed in the molten mass and a basal region that in use fits sealingly into the lining. A core is a close fit into the electrode body and projects from one end thereof. At least the outer surface of the core is of a metal that is non-reactive with the material of the refractory ceramic electrode at the temperature of the molten mass and that is itself molten at said temperature so that in use of the electrode the metal in the terminal region melts and establishes an intimate contact between the core and the electrode body. A connector comprises a socket in which core projecting from the electrode body fits to establish a current path to the electrode and a sleeve surrounding the socket and defining an abutment for the electrode body.

Abstract: Glass is made from a feed consisting of batch materials and cullet in a furnace that is both electrically and gas fired. A batch-only hopper discharges through a blanket conveyor to a batch melting chamber that is electrically fired and is connected via a submerged throat to a fritting chamber where the at least partly molten batch materials are mixed with cullet fed from cullet-only hoppers by blanket feeders. The fritting chamber is fired by a combination of electricity and roof-mounted flat flame burners. Material passes from the fritting chamber to a secondary reheating and refining chamber which is heated by regenerative gas burners. The separation of batch materials from cullet and separate melting thereof in a pre-melter means that the feed to the secondary refining and conditioning chamber is relatively free of fines and requirement to melt only cullet in the fritting chamber and secondary refining chamber enables those chambers to be operated at a lower temperature than the batch melting chamber.