CFD simulation of the increased electric boost effects on the glass melting process in a real glass furnace to support decarbonisation of glass industry

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Abstract The glass industry plays a pivotal role in modern manufacturing, providing essential materials for a multitude of applications ranging from construction to consumer goods. However, the substantial energy demands, primarily driven by the intense heat required to melt raw materials within furnaces, pose significant challenges. Traditionally, thermal energy is sourced from combustion processes in dedicated chambers. Yet, in the pursuit of efficiency and environmental sustainability, there is a growing preference for integrated systems. Notably, the utilization of electrode installations within glass baths emerges as a promising choice for direct melting augmentation through electricity in a more efficient way. This study introduces a sophisticated computational fluid dynamics (CFD) model, developed by the authors, tailored to simulate the real operation of a glass furnace. The model fully couples the reactive flow in the combustion space (the furnace) with convective motions within the glass tank including the effect of the electrodes. By changing the thermal energy from combustion with varying levels of electrode operation (keeping the same overall heat flux to the glass), the furnace behaviour is investigated. The research specifically examines the effects of electrode operation on crucial furnace parameters, including flame heat release and convective motions inside the glass bath, across different scenarios. Insights are gained into the complex interplay between electrode operation, thermal dynamics, and glass quality within the furnace environment. The findings of this study not only deepen the understanding of fundamental processes within glass manufacturing but also offer actionable insights for industry stakeholders. By elucidating the intricate relationship between electrode operation and glass melting process, this research provides practical guidance for optimizing furnace design and operation, enhancing efficiency and CO2 reduction, with the same product quality, in the glass industry.