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, the substantially vertical wall comprising two opposing substantially vertical side walls, a substantially vertical inlet end wall, and a substantially vertical outlet end wall, a melting zone being defined by the floor, ceiling and the substantially vertical wall, the melting zone having a feed inlet in the substantially vertical inlet end wall and a molten glass outlet in the substantially vertical outlet end wall, the substantially vertical inlet end wall and the substantially vertical outlet end wall positioned at opposing ends of the melting zone, the melting zone comprising an expanding zone beginning at the substantially vertical inlet end wall and extending to an intermediate location relative to the opposing ends of the melting zone, and a narrowing zone extending from the intermediate location to the substantially vertical outlet end wall, the intermediate location comprising a constant width zone positioned between the expanding zone and the narrowing zone, wherein at least some of the substantially vertical wall comprises fluid-cooled refractory panels, the two opposing substantially vertical side walls in the narrowing zone each having a free flowing form, and the two opposing substantially vertical side walls in the expanding zone each being linear and intersecting the substantially vertical wall in the constant width zone at an angle larger than 90 degrees;
• 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 melting 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 substantially vertical wall comprising two opposing substantially vertical side walls, a substantially vertical inlet end wall, and a substantially vertical outlet end wall, the melting zone comprising an expanding zone beginning at the substantially vertical inlet end wall and extending to an intermediate location relative to opposing ends of the melter, and a narrowing zone extending from the intermediate location to the substantially vertical outlet end wall, at least the substantially vertical side walls in the narrowing zone each having a free flowing form devoid of 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 melting zone;
• and
• discharging molten glass from a molten glass outlet positioned in the substantially vertical outlet end wall.

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 substantially vertical wall comprising two opposing substantially vertical side walls, a substantially vertical inlet end wall, and a substantially vertical outlet end wall, the melting zone comprising an expanding zone beginning at the substantially vertical inlet end wall and extending to an intermediate location relative to opposing ends of the melter, and a narrowing zone extending from the intermediate location to the substantially vertical outlet end wall, the intermediate location comprising a constant width zone positioned between the expanding zone and the narrowing zone, and with the two opposing substantially vertical side walls in the narrowing zone having a free flowing form, and the two opposing substantially vertical side walls in the expanding zone each being linear and intersecting the substantially vertical wall in the constant width zone at an angle larger than 90 degrees;
• 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 melting zone;
• cooling the substantially vertical wall by the substantially vertical wall comprising cooled refractory panels and directing a heat transfer fluid through the cooled refractory panels;
• and
• discharging molten glass from a molten glass outlet positioned in the substantially vertical outlet end wall.