Methods and apparatus for recycling glass products using submerged combustion
A method for recycling glass mat waste, wound rovings, and other products includes providing a source of glass mat, or a plurality of rovings, for example on a roll, and routing the glass mat or rovings into a submerged combustion melter. An unwind system and a pair of powered nip rolls, powered conveyors, or other arrangement may work in combination to provide a substantially consistent rate of material into the melter. The melter may operate under less than atmospheric pressure to avoid fumes escaping the melter. A slot in the melter allows ingress of the glass mat or rovings into the melter, and a glass mat former such as a folder may be used to ensure that the mat fits through the slot. Alternatively, the glass mat may be cut by a slitter prior to entering the slot.
1. A method of recycling glass mat ( 18 ) materials, comprising:
a) providing a source ( 16 ) of glass mat ( 18 ), wherein the glass mat ( 18 ) is selected from the group consisting of nonwoven and woven materials;
b) routing the glass mat ( 18 ) at a substantially consistent feed rate into a submerged combustion melter ( 2 ) through a slot ( 26 ) in the melter ( 2 ) and then directly into a well-mixed mass of molten glass ( 4 ) within the melter ( 2 ) and melting the glass mat ( 18 ), wherein the melting comprises at least one burner ( 8 ) directing combustion products into a melting zone under a level ( 6 ) of the well-mixed molten glass ( 4 ) in the zone, and wherein the routing comprises unwinding the glass mat ( 18 ) off of a roll ( 16 ) of glass mat using an unwind system ( 14 , 15 ) and a mechanism ( 24 ) selected from the group consisting of a pair of powered nip rolls, a nip compression conveyor, and opposed conveyors compressing the product.
2. The method of claim 1 wherein the glass mat ( 18 ) is routed through a forming device ( 20 ) prior to entering the powered nip rolls ( 24 ) so that the glass mat ( 18 ) fits through the slot ( 26 ).
3. The method of claim 1 wherein the glass mat ( 18 ) is cut to width prior to entering the powered nip rolls ( 24 ) so that it fits through the slot ( 80 , 90 , 110 , 120 150 ).
4. The method of claim 1 wherein the providing the source ( 16 ) of glass mat ( 18 ) comprises providing a web of substantially continuous glass fibers bound together randomly at points where adjacent fibers touch using a binder.
5. The method of claim 1 wherein the unwinding of the glass mat ( 18 ) comprises splicing a first web unwinding from a first roll to a second web unwinding from a second roll.
6. A method of glass fiber roving ( 152 ) materials, comprising:
a) providing a source ( 16 ) of glass fiber roving ( 152 );
b) routing the glass fiber roving ( 152 ) at a substantially consistent feed rate into a submerged combustion melter ( 2 ) through a slot ( 26 ) in the melter ( 2 ) and then directly into a well-mixed mass of molten glass ( 4 ) within the melter ( 2 ) and melting the glass fiber roving ( 152 ), wherein the melting comprises at least one burner ( 8 ) directing combustion products into a melting zone under a level ( 6 ) of the well-mixed molten glass ( 4 ) in the zone, and wherein the routing comprises unwinding the glass fiber roving ( 152 ) off of a roll ( 16 ) glass fiber roving using an unwind system ( 14 , 15 ) and a mechanism ( 24 ) selected from the group consisting of a pair of powered nip rolls, a nip compression conveyor, and opposed conveyors compressing the product.
7. The method of claim 6 wherein the glass fiber roving ( 152 ) is routed through a forming device ( 20 ) prior to entering the powered nip rolls ( 24 ) so that the glass fiber roving ( 152 ) fits through the slot ( 26 ).