Modelling Annealing Lehrs For Flat Glass: Robert Gardon
Modelling Annealing Lehrs For Flat Glass: Robert Gardon
Modelling Annealing Lehrs For Flat Glass: Robert Gardon
ROBERT GARDON*
Research Staff, Ford Motor Company, Dearborn, Michigan 48 121
Computer simulationof heat transfer in annealing lehrs for flat residual midplane tension (or surface compression) “frozen” into
glass is combined with a method developed earlier for the the glass. No account is taken of membrane stresses.*
calculation of stresses in glass. With this combined model one
can predict stresses produced by annealing schedules that are 11. Development of Lehr Model
readily realized in practice. Implications for the design, opera- (1) Description of Lehr
tion, and energy economy of lehrs are discussed.
Annealing lehrs for flat glass are divided lengthwise into zones
and the design of each zone is tailored to local temperatures of the
I. Introduction glass. A zone in the “annealing section” of a lehr consists of an
insulated shell, through which the glass ribbon is transported on
T HE advantage of annealing glass by cooling it at progressively
higher rates has long been known, ‘ even though annealing
stresses could be predicted analytically only if glass was cooled
rollers. The particular design3 considered in this paper is shown
schematically in Fig. 1. It was chosen for its simplicity, which
allows essential features of lehr operation to be illustrated with a
through the entire annealing range at one constant rate.* Annealing
minimum number of design and operating parameters. In zones of
lehrs have therefore been designed largely on the basis of experi-
this type, the glass ribbon is cooled by countercurrent streams of
ence, and rather conservatively. To modulate cooling rates -or
air flowing through two banks of tubes, one above and one below
even only to control them more closely -annealing lehrs for flat
the ribbon. The air (coolant) may pass through a zone just once, or
glass are divided into “zones,” each of which is, in effect, a
it may be recirculated in order for its inlet temperature to be raised
separate heat exchanger. In the conventional view, cooling rates in
above room temperature at a minimum cost in energy.
each zone are regarded as constant. However, it has also become
recognized that cooling rates can change not only between zones (2) Heat Transfer in Lehr
but also within zones.3 At temperatures in the annealing range the dominant mecha-
The starting point of the present considerations was the develop- nisms of heat transfer involved in cooling the glass are radiation
ment of methods to calculate stresses produced in glass subjected from the glass to the tubes and forced convection from the tubes to
to an arbitrary heat treatmer~t.~-~ In particular, Ref. 6 showed that, the cooling air. Heat transfer by natural convection within the
given the temperature-time history of a small glass plate, the re- “tunnel,” i.e. from the glass to the air in the tunnel and from the
sulting annealing stresses can be predicted with a high measure of air to the tubes and walls of the lehr, is relatively small and could
reliability. To apply these laboratory findings to annealing on an be neglected without affecting the conclusions of this study. (It
industrial scale entails two tasks: One is to analyze heat transfer in becomes important in cooling the glass at lower temperatures.)
an annealing lehr with a view to determining the temperature-time The roof and floor of the lehr are insulated and essentially
history of the glass as a function of lehr design and operating adiabatic. Radiation from the glass to these surfaces is therefore
conditions. The second is to predict annealing stresses from this reradiated to the nearby tubes, thus augmenting the direct radiant
temperature-time history and the relevant physical properties of exchange between the glass and the tubes.” Heat losses through
the glass. side walls and along roller journals are not negligible and they are
A computer program LEHR was written to do that, and this largely responsible for the preferential cooling of the edges of the
paper reports some of the findings made in using it to study the glass ribbon and, hence, for membrane stresses. However, in line
design and operation of annealing lehrs for float glass. For the with the intention of leaving such stresses out of account for the
present we will be concerned only with those aspects of lehrs that present, these sideways heat losses are not considered, and the
affect the generation of ordinary annealing stresses, i.e. of the temperature distribution in the glass ribbon is treated as one-
dimensional, i.e. as varying primarily along its length. (The con-
Presented at the 83rd Annual Meeting, The American Ceramic Society, Washing- comitant temperature variation through the thickness of the glass
ton, D . C . , May 5 , 1981 (Glass Division No. 21-G-81). Received September 25,
1981; revised copy received February 4, 1982 is, of course, vital to the generation of annealing stresses, but it has
*Member, the American Ceramic Society. virtually no effect on heat transfer in the lehr.)
With these provisions, the principal design parameters of a lehr
Return
TC Air
” Intake
’-..
e are the number of zones into which it is divided, the lengths of the
zones, and the diameter and spacing of the cooling tubes used in
Duct txnaust the various zones. Neglecting edge effects and considering only the
central region of a wide ribbon, the distance between the ribbon
and the plane of the tubes is not a significant variable. The same
Fan
*Membrane stresses are stresses in the plane of the glass that may be superimposed
I ‘I
372
August 1982 Modelling Annealing Lehrs for Flat Glass 373
goes for the wall thickness of the tubes. The important operating 600
parameters include, first, the thickness and velocity of the glass TAC SCMR PWR
ribbon to be annealed. They determine the mass flow rate of the OC n m / c m kW/m
glass and remain the same throughout the lehr. All other operating Linear 214 -
parameters must be defined for each zone. They include the desired 25 195 2.3
glass temperatures at the ends of each zone and the mass flow rates 200 2t3 127
and inlet and outlet temperatures of the cooling air for each zone.? 300 28 2 95
Altogether, the thermal model of the lehr is a relatively simple
one, intended mainly to highlight effects of the most important
variables. Secondary heat transfer mechanisms may also have to be
taken into account in calculations intended for actually designing
a lehr. EQ 500
(3) Computer Simulation of a Lehr
The computer program LEHR calculates glass temperatures
from operating conditions of the lehr and annealing stresses in the
glass from these temperatures, taking into account both stress and
structural relaxation in the glass.4 It may be used in several differ-
ent ways.
In the “design” mode it will calculate the lengths of the zones
required to attain desired interzonal glass and coolant temperatures
for specified glass and coolant flows, using cooling tubes in a
specified arrangement. 400
More generally, the design of a lehr and all parameters pertaining 0 10 20 30 40
to the glass ribbon will be specified. Of the three parameters Position Along Lehr, X [rn]
defining the coolant stream in each zone, one may be chosen more
or less at will. The other two must then be determined by the Fig. 2. Longitudinal temperature distributions in a glass ribbon
simultaneous solution of the heat balance for the zone and the annealed in one zone with cooling air at various temperatures
equations governing heat transfer. The program LEHR can there- (cf. example 1).
fore also be operated in several “running” modes, depending on
which operating parameters one wishes to vary at will.
and how this, in turn, affects the annealing stresses they produce
There is also a ‘‘linear’’ mode to simulate the performance of
and the energy economy of their operation. Individual results and
lehrs as they are commonly conceived. In this mode, heat transfer
their preliminary discussion are presented in this section. More
in the lehr is not considered, and LEHR simply calculates an-
discussion, pulling together results from several examples, follows
nealing stresses in a glass ribbon on which a cooling schedule in Section IV.
consisting of zone-wise constant cooling rates is impressed.
All examples deal only with the “hot end” of lehrs, i.e. with
In the examples illustrating this paper, coolant streams are speci-
cooling glass through the annealing range and a little below it. The
fied by the desired air inlet temperature to each zone. Calculations
number of zones involved will be varied, as will their lengths.
must therefore begin with a determination of the coolant flow rates
However, all will have cooling elements constructed of 7.5-cm-
required to operate the lehr. The sequence of calculations is thus:
diameter tubes with a center-to-center spacing of 15 cm. All
( 1 ) For each zone, LEHR finds that combination of coolant flow
will be used to anneal a 3-mm-thick glass ribbon that is being
rate and coolant outlet temperature which, together with the speci-
produced at a speed of 21 cm/s.* Terminal temperatures of the
fied coolant inlet temperature, will simultaneously satisfy the heat
glass and flow rates and terminal temperatures of the coolant will
balance for the specified temperature drop of the glass and the
be varied with a view to exploring their influence on the per-
conditions for the requisite heat transfer. formance of lehrs.
(2) LEHR then calculates the longitudinal temperature distribu-
tion in the glass ribbon, which is equivalent to determining how (1) Annealing in Only One Zone
cooling rates of the glass vary along the zone. The examples of this section serve two purposes. They consti-
(3) Steps 1 and 2 are repeated for all zones in the annealing tute a first look at heat transfer in a lehr and at how cooling rates
section of the lehr, taking the calculated outlet temperature of the vary -or can be made to vary -within a single zone. Second, by
glass from one zone as the inlet temperature to the next. cooling the glass ribbon through the entire annealing range (from,
(4) From the temperature distribution in the ribbon throughout say, 600” to 400°C) in just one zone, one can also explore the
the annealing section, LEHR calculates transient stresses in the extent to which modulation of cooling rates in one zone can affect
glass ribbon as it is being cooled and the residual (annealing) stress the state of anneal produced.
frozen into the ribbon as it passes out of the annealing range. Example I : The first such single annealing zone to be consid-
( 5 ) Finally, to facilitate energy considerations, LEHR also calcu- ered is 40-m long and operated with various coolant inlet tem-
lates the enthalpy of the air inlet and outlet streams, the heat peratures, TAC.$ Figure 2 shows that different coolant inlet tem-
extracted from the glass (by difference), and the power dissipated peratures produce quite different thermal histories in the same glass
by the flow of the cooling air through the lehr. ribbon, cooled through the same temperature interval. For a low
TAC, such as 25”C, the temperature distribution along the glass
111. Results of Computer Simulations of Lehrs ribbon is “convex up,” which means that the cooling rate of the
glass increases as the glass passes through the lehr. The opposite
Considering the great variety of lehrs and the large number of holds for a high TAC, such as 300°C. The change in shape of these
variables involved in their design and operation, generalizations temperature distributions can readily be explained. (Cf. below and
about them may be both hard to come by and hazardous to use. The Section IV(l).) The important point to note is that the increasing
approach taken here is to present the results of computer simu- cooling rate that goes with a convex temperature distribution is
lations of a series of comparable-and progressively more what one usually seeks to achieve in successive zones of a con-
complicated -lehrs, and to examine their thermal performance ventional, multizone lehr, and here we see that it can also be
’To control the lateral uniformity of glass temperatures and thus avoid membrane obtained in a single zone.
stresses, different cooling tubes-or groups of tubes-may, in practice, have separate
air supplies. The upper and lower tube banks may also be operated differently to ‘In designing a lehr, one would also have to consider its performance on glass
compensate for the interference of rollers with heat transfer. In the present analysis this ribbons of different thicknesses, notably on the thickest ribbon to be processed at the
interference is neglected and all tubes in a zone are taken to be supplied with air at hi hest applicable rate.
the same temperature and at the same flow rate. %or definitions of symbols, see footnote to Table 1.
374 Journal of the American Ceramic Society-Gardon Vol. 65, No. 8
Table I. Performance of a Single Zone (40 meters Long) Table 11. Performanceof a Single Zone (60 meters Long)
Cooling Glass Ribbon From 600 to 400°C (Example 1)* (Examples 2 and 3)
TAC A-G TAH RH RC RH-RC SCMR PWR TAC A-G TAH RH RC RH-RC SCMR PWR
("0 ("C) ("C/S) ("C/S) (nm/cm) (kW/m) ("C) ("C) ( W S ) (T/s) (nm/cm) (kW/m)
-Linearcooling- 1.05 1.05 1.00 21.4 - Glass cooled from 600"to 400°C [Example 2)
25 0.38 550 0.40 1.42 0.28 19.5' 2.3 -Linear cooling- 0.70 0.70 1.00 14.3 -
50 0.40 545 0.45 1.38 0.33 19.5 2.8 25 0.36 596 0.09 1.41 0.064 15.3. 2.8
100 0.46 537 0.55 1.28 0.43 19.6 4.3 100 0.42 583 0.14 1.26 0.11 14.2 5.0
200 0.64 510 0.89 1.03 0.86 20.9 12.8 200 0.54 569 0.29 1.00 0.29 13.2* 12.1
220 0.71 503 0.99* 0.97' 1.02 21.4 17 292 0.80 541 0.65+ 0.67t 0.98 14.3 40
300 1.28 456 1.70 0.65 2.59 28.2 95 300 0.85 535 0.72 0.62 1.17 14.7 48
~ ~ ~~~ ~
The average cooling rate of the glass is I.O5"C/s. Cooling rate, so that the power required to operate this zone with linear
the glass at this rate throughout the zone, i.e. "linear" cooling, cooling would now become much higher (40 kW/m width of lehr).
would produce a residual midplane tension ("annealing stress") of However, as before, there is really no advantage in operating the
21.4 nm/cm.n However, one can also do better than that. Thus, for lehr in this manner. The same residual stress can also be obtained
example, using a coolant inlet temperature of 25"C, one can reduce with a TAC of IOO'C, at a cost in power of only 5 kW/m. Opera-
the residual stress to 19.5 nm/cm. tion with a coolant inlet temperature of 200°C would yield the
Table I illuminates the performance of this "single-zone lehr" in lowest residual stress obtainable with this zone, though it is ques-
greater detail. It shows that a virtually constant cooling rate can be tionable whether the slight reduction in stress to 13.2 nm/cm is
achieved in practice with an air inlet temperature of 220°C and an worth the considerable increase in power consumption to
air rate corresponding to which the ratio (A/G) of the heat capaci- 12.1 kW/m.
ties of the air and glass streams is 0.71. It is interesting to note that In this example the lowest stress is not obtained with the lowest
this is significantly less than the air-rate corresponding to coolant inlet temperature, as it was in the shorter zone. Operating
A/G= 1 .O, which would be required for linear cooling in a heat the 60-m zone with a coolant inlet temperature of 25°C still leads
exchanger in which a constant overall heat transfer coefficient was to the lowest power requirement, but yields a somewhat higher
applicable. (In annealing lehrs the "effective" overall heat transfer residual stress than the quasi-optimal operation with a TAC of
coefficient can vary considerably along the length of a zone on 200"C, or even linear cooling. To be sure, the longer zone pro-
account of the strong temperature dependence of the rate of radiant duces lower stresses under all operating conditions, but that
heat transfer. To maintain a constant cooling rate in spite of this is as expected, and it is obtained at a considerable increase in
variation, the higher heat transfer coefficient at the hot end of a capital cost.
zone must be offset by a locally smaller overall temperature differ- The conclusion to be drawn here is that cooling, even within a
ence between the glass and coolant, which, in turn, requires that single zone, will not, in general, be linear. Departure from linearity
A/G in a countercurrent heat exchanger be less than unity.) may help or hurt, for it may decrease or increase the annealing
The lower annealing stress of 19.5 nm/cm, produced with a stress produced in a given length of lehr. The important point is that
TAC of 25"C, is obtained with a cooling schedule in which the cooling rates can be varied in a constructive manner even within a
cooling rate increases from O.4O0C/s at the hot end of the zone to single zone and there is no intrinsic merit to cooling glass at a
1.42 at the cold end, i.e. by a factor of 1/0.28. The required constant rate. While the residual stress produced for prescribed
coolant flow rate corresponds to an A/G ratio of only 0.38. Con- conditions of glass production depends primarily on the length of
versely, with a coolant inlet temperature of 300°C the residual lehr available to cool the glass through the annealing range, modu-
stress would go up to 28.2 nm/cm. lation of the cooling rate--even within a single zone-can also
The advantage of operating with a low coolant inlet temperature have a marked effect. .
becomes even more pronounced when one considers the power Example 3: For the last example of this series, a 60-m-long
dissipated by the flow of the cooling air through the lehr. This is zone is used to cool the glass ribbon of the preceding examples
only 2.3 kW/m width of lehr for an air inlet temperature of 25", from 600" to 300"C, i.e. through a temperature interval 1.5 times
as against 95 kW/m for an air inlet temperature of 300°C. The as large as before. The average cooling rate through the 60-m zone
lower power requirement for the lower coolant inlet temperature thus becomes the same as it was in the 40-m zone of the first
arises principally from the fact that less coolant is required. example, so that linear cooling through the entire zone should
Example 2: The lowest coolant inlet temperature and most again produce an annealing stress of 21.4 nm/cm. (Cf. lower part
strongly convex temperature distribution is not always the most of Table 11.)
favorable one. This is shown in the upper part of Table 11, which It turns out that-taking 25°C to be the lowest practicable
summarizes the results of calculations similar to the above, but for coolant inlet temperature -it is impossible in practice to attain this
a zone that is 60-m long. stress with this lehr. The problem with attempting to cool the glass
In line with the lower average cooling rate, linear cooling of the through so wide a temperature interval in a single zone is that the
glass in this longer lehr would produce a residual midplane tension coolant must pick up a large amount of heat before it reaches that
of only 14.3 nm/cm. Whereas in the previous example nearly part of the zone in which the glass is cooled through the annealing
linear cooling could be achieved in practice with a coolant inlet range. The conditions for picking up this heat, at the cold end of
temperature of 220°, now a coolant inlet temperature of 292°C the zone, would be unfavorable because the rate of radiant heat
would be required. Offsetting the advantage of a longer lehr, this transfer from the glass to the tubes is sharply lower at low tem-
higher coolant temperature would require a higher coolant flow peratures. To offset this, the system would call for higher air rates,
which produce higher convective heat transfer coefficients in the
"This is really a stress-induced birefringence, which corresponds to a stress of tubes and maintain larger temperature differences between the
7.9 kg/crn ( I 13 psi). Since the only way to measure such internally balanced stresses
is via the birefringence they produce, the term ''stress'' will be used, for brevity, even glass and coolant. These factors would also enhance heat transfer
where measures of stress-induced birefringence are cited. at the hot end of the zone, so that the heat transfer rate there would
August 1982 Modelling Annealing Lehrs for Flat Glass 375
Table 111. Performance of a “Two-Zone”Lehr (40 meters Long) Cooling Glass Ribbon From 600”to 4OO0C*
Example Zone TAC A-G TAH RH RC RH-RC SCMR PWR
No. No. (“C) (“C) (“CIS) (“C/s) (nmlcm) (kwlm)
Zone-wise linear cooling
4.L 1 0.61 0.61 1 .oo
2 1.71 1.71 1.oo
End result/Total 16.6 -
become very high. Thus, relatively little heat would be transferred 600
in the major part of the zone near its cold end and a great deal in TAC 1
a short region near the hot end, so that cooling curves would be O C
-
350 TAC2 SCMR PWR
OC n m / c m kW/n
300 15.0 3.3
-0
(3
400 14.5 7.9
F
L
a,
L
-
1
500-
0)
a
E
-
100
? -
I I I u)