Computational experiments to characterize bubble formation and movement in waste glass foam layer
Computer simulation experiments are a valuable complement to physical experimentation for systems where there is limited access to quantities of interest. The motivation for this work is to characterize the fluid dynamic and heat transfer processes that affect melt rate of waste slurry during vitrification, which can limit the throughput rate of the melter. Heat transfer to the cold cap from the molten glass below this layer is an important factor determining melt rate. In this study, computational fluid dynamics is used to elucidate the behavior of gas-filled cavities that form underneath the cold cap in a laboratory-scale waste glass melter. The cold cap consists of a reacting feed layer above a foam layer. The cavities are a result of coalesced gases from collapsing primary foam and air from forced convection bubblers. Bubbles in the foam layer move horizontally with the circulation pattern of the melt and escape around the edges of the cold cap to the plenum above. The effects of varying thermophysical properties and foam parameters based on the bounds of high-level waste glass formulations were explored. Using the DAKOTA toolkit, a Latin hypercube space-filling design was used to randomly distribute samples in bins to achieve good coverage over the parameter space with minimal points. Using the results from the set of simulations, a Gaussian process model with a linear trend was used to create response surfaces for several key quantities of interest, including temperatures, temperature gradients, velocities, and foam extent beneath the cold cap.