Effective discharge of exhaust from submerged combustion melters and methods

A submerged combustion manufacturing method comprising:

• melting materials in a submerged combustion melter (SCM) equipped with one or more submerged combustion (SC) burners, the SCM having a length (L) and a width (W), a centerline (C), a midpoint (M), a sidewall structure having a north side (N) and a south side (S), the sidewall structure connecting a ceiling and a floor of the SCM, the SCM comprising one or more exhaust passages through the sidewall structure;
• combusting a fuel in the one or more SC burners, the one or more SC burners discharging combustion products under a level of the materials being melted in the SCM and creating turbulent conditions in substantially all of the materials being melted as well as ejected portions of melted material;
• and
• exhausting exhaust materials from the SCM through an exhaust structure fluidly connecting the one or more exhaust passages with an exhaust stack, the exhaust structure comprising:
• a liquid-cooled exhaust structure of height H1 fluidly connected to the one or more exhaust passages, the liquid-cooled exhaust structure defining a liquid-cooled exhaust chamber having a first interior surface, the liquid-cooled exhaust chamber having a cross-sectional area greater than that of the exhaust stack but less than the SCM,
• the one or more exhaust passages and liquid-cooled exhaust structure maintaining temperature and pressure of the exhaust materials from the SCM, and exhaust velocity of the exhaust materials from the SCM through the exhaust structure, at values sufficient to prevent the ejected portions of melted material from being propelled out of the exhaust structure and into the exhaust stack as solidified material, and maintain any molten materials contacting the first interior surface molten so that it flows back down the first interior surface back into the SCM, and
• a gas-cooled exhaust structure of height H7 fluidly connecting the liquid-cooled exhaust structure and the exhaust stack, the gas-cooled exhaust structure defining a gas-cooled exhaust chamber having a second interior surface, the gas-cooled exhaust structure consisting of a metal layer forming the second interior surface, the metal layer having one or more gas-cooled external surfaces, the gas-cooled exhaust structure devoid of refractory or other lining,
• wherein H1 is greater than or equal to H7, and H7 is not 0.