Chemistry, physics and time: the computer modelling of glassmaking

A decade or so ago the remains of an early flat glass furnace were discovered in St Helens. Continuous glass production only became feasible after the Siemens Brothers demonstrated their continuous tank furnace at Dresden in 1870. One manufacturer of flat glass enthusiastically adopted the new technology and secretly explored many variations on this theme during the next fifteen years. Study of the surviving furnace remains using today's computer simulation techniques showed how, in 1887, that technology was adapted to the special demands of window glass making. Heterogeneous chemical reactions at high temperatures are required to convert the mixture of granular raw materials into the homogeneous glass needed for windows. Kinetics (and therefore the economics) of glassmaking is dominated by heat transfer and chemical diffusion as refractory grains are converted to highly viscous molten glass. Removal of gas bubbles in a sufficiently short period of time is vital for profitability, but the glassmaker must achieve this in a reaction vessel which is itself being dissolved by the molten glass. Design and operational studies of today's continuous tank furnaces need to take account of these factors, and good use is made of computer simulation techniques to shed light on the way furnaces behave and how improvements may be made. This paper seeks to show how those same techniques can be used to understand how the early Siemens continuous tank furnaces were designed and operated, and how the Victorian entrepreneurs succeeded in managing the thorny problems of what was, in effect, a vulnerable high temperature continuous chemical reactor.