Panel-cooled submerged combustion melter geometry and methods of making molten glass

A melter apparatus comprising:

• a) a floor and a ceiling;
• b) a substantially vertical wall connecting the floor and ceiling at a perimeter of the floor and ceiling, a melting zone being defined by the floor, ceiling and wall, the melting zone having a feed inlet and a molten glass outlet positioned at opposing ends of the melting zone, the melting zone comprising an expanding zone beginning at the inlet and extending to an intermediate location relative to the opposing ends, and a narrowing zone extending from the intermediate location to the outlet, wherein at least some of the wall comprises fluid-cooled refractory panels, and with the wall having a free flowing form devoid of 90 degree angles;
• and
• c) a plurality of burners, at least some of which are positioned to direct combustion products into the melting zone under a level of molten glass in the zone.

A process comprising:

• feeding at least one partially vitrifiable material into a feed inlet of a melting zone of a refractory melter apparatus comprising a floor, a ceiling, and a substantially vertical wall connecting the floor and ceiling at a perimeter of the floor and ceiling, the melting zone comprising an expanding zone beginning at the inlet and extending to an intermediate location relative to opposing ends of the melter, and a narrowing zone extending from the intermediate location to a molten glass outlet, and with the wall having a free flowing form devoid of 90 degree angles;
• heating the at least one partially vitrifiable material with at least one burner directing combustion products into the melting zone under a level of the molten glass in the zone;
• and
• discharging molten glass from a molten glass outlet positioned at an end of the melting zone opposite the inlet.

A process comprising:

• feeding at least one partially vitrifiable material into a feed inlet of a melting zone of a refractory melter apparatus comprising a floor, a ceiling, and a substantially vertical wall connecting the floor and ceiling at a perimeter of the floor and ceiling, the melting zone comprising an expanding zone beginning at the inlet and extending to an intermediate location relative to opposing ends of the melter, and a narrowing zone extending from the intermediate location to a molten glass outlet, and with the wall having a free flowing form devoid of 90 degree angles;
• heating the at least one partially vitrifiable material with at least one burner directing combustion products into the melting zone under a level of the molten glass in the zone;
• cooling the wall by the wall comprising cooled refractory panels and directing a heat transfer fluid through the panels;
• and
• discharging molten glass from a molten glass outlet positioned at an end of the melting zone opposite the inlet.