A system for forming a foamy molten batch of glass using a submerged combustion melter, and manufacturing foamed glass and dense glass from the same foamy molten batch of glass, the system comprising:
- a submerged combustion melter comprising a melting zone defined by 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 having a molten glass outlet, the melter devoid of a refining zone, the melting zone halving a feed inlet for receiving at least one partially vitrifiable material through a batch feed chute, the batch feed chute and the molten glass outlet positioned at opposing ends of the melting zone, the melting zone having 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 molten glass outlet, and a plan view shape selected from the group consisting of:
- i) defined by first and second trapezoids sharing a common base positioned at the intermediate location and substantially perpendicular to a longitudinal axis of the melter, the first trapezoid having a side parallel to the base and positioned at the feed inlet, the second trapezoid having a side parallel to the base and positioned at the molten glass outlet;
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- ii) a non-symmetrical plan about an axis substantially perpendicular to a longitudinal axis of the melter, wherein the substantially vertical wall in the expanding zone and the narrowing zone is non-linear,
- and a plurality of submerged combustion burners, at least some of which are positioned to direct combustion products into the expanding zone and the narrowing zone under a level of molten glass in the expanding zone and the narrowing zone,
- the melter molten glass outlet fluidly connected to an inlet of a refractory or refractory-lined channel having width, depth, and length and having an end weir with an overflow outlet, and a bottom throat;
- a conveyor fluidly connected to and downstream of the refractory or refractory-lined channel, the conveyor having a first end positioned to accept foamy molten glass from the overflow outlet of the refractory or refractory-lined channel, the conveyor comprising heat-resistant components and devoid of gas injectors, the end weir positioned in the refractory or refractory-lined channel just upstream of the conveyor first end, the bottom throat positioned at the bottom of the refractory or refractory-lined channel and upstream of the end weir, the bottom throat fluidly connecting the refractory or refractory-lined channel with a downstream dense glass processing apparatus;
- the conveyor dimensioned to accept the foamy molten glass on it to form a continuous ribbon of foamed molten glass having varying thickness and varying width, and
- the downstream dense glass processing apparatus dimensioned to accept denser molten glass and form one or more dense glass products.