Radiative Heat transfer and Applications for

Glass Production Processes

Axel Klar and Norbert Siedow

Department of Mathematics, TU
Kaiserslautern
Fraunhofer ITWM Abteilung
Transport processes
Montecatini, 15. 19. October 2008

Glass 1

ITWM Activities in Glass

Glassmaking
Shape optimization of thermal-electrical
flanges
Temperature
(Impedance
Tomography)
PATENT

Coupling of glass
tank with electrical
network

Gob temperature
(Spectral remote
sensing)

Form of the gob

(FPM)

Glass 2

ITWM Activities in Glass

Glassprocessing I
Pressing
TV panels
Lenses

Floatglass
window glasses
display glasses

Blowing
Bottles

Interface Glass-Mould (Radiation)

Identification of the heat transfer
coefficient
High precision forming
Wavyness of thin display glasses

...
Foaming

Minimization of thermal stresses

Optimal shape of the furnace

Fiberproduction

Fluid-Fiber-Interaction

Glass 3

ITWM Activities in Glass

Glassprocessing II
Free cooling

Simulation of
temperature field

Cooling in a
furnace

Control of furnace
temperature to minimize
the thermal stress

Tempering of glass

Glass 4

Radiative Heat transfer and Applications for Glass Production

Processes
Planning of the Lectures
1.

Models for fast radiative heat transfer simulation

2.

Indirect Temperature Measurement of Hot Glasses

3.

Parameter Identification Problems

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Models for fast radiative heat transfer

simulations

N. Siedow
Fraunhofer-Institute
for Industrial Mathematics,
Kaiserslautern, Germany

Montecatini, 15. 19. October 2008

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Models for fast radiative heat transfer simulations

Outline
1.

Introduction

2.

Numerical methods for radiative heat transfer

3.

Grey Absorption

4.

Application to flat glass tempering

5.

Conclusions

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Models for fast radiative heat transfer simulations

1. Introduction
Temperature is the most important parameter in all stages of glass
production

Homogeneity of glass melt

To determine the
temperature:

Drop temperature

Thermal
stress
Measurement Simulation

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Models for fast radiative heat transfer simulations

1. Introduction
microscale
nm

mm cm

Conductivity in W/(Km)

Heat transfer on a

With Radiation

Without Radiation
Temperature in C

Heat radiation on a
macroscale

Radiation is for high

temperatures the dominant
process

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Models for fast radiative heat transfer simulations

1. Introduction
Heat transfer on a
microscale
nm

mm cm

T r
r
r
r
(r , t ) (k ( r ) T (r , t )) qr (T ) , (r , t ) Dt
t
r
r
r
T (r , 0) T0 (r ), r D
cm m

+ boundary
conditions

r r r
r
r
qr I (r , , )d d
0 S2

Heat radiation on a

r
r r
r r
r
I (r , , ) ( ) I (r , , ) ( ) B(T ( r , t ), )

I (rg , , ) () I (rg , ' , ) (1 ()) B (Ta , )

macroscale

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Models for fast radiative heat transfer simulations

2. Numerical methods for radiative heat transfer
Heat transfer on a
microscale

Rosseland-Approximation

nm

Radiation = Correction of Conductivity

PN-Approximation
mm cm

Discrete-Ordinate-Method (FLUENT)

Heat radiation on a

ITWM-Approximation-Method

macroscale

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Models for fast radiative heat transfer simulations

2. Numerical methods for radiative heat transfer
r
r r
r r
r
Klar: I (r , , ) ( ) I ( r , , ) ( ) B (T ( r , t ), )
We study the optically thick case. To obtain the dimensionless form of
the rte we introduce

r ' r / rref

' / ref

and define the non-dimensional parameter

1
ref xref

which is small in the optically thick diffusion regime.

r r
r r
r
I (r ', , ) I (r ', , ) B(T , )
'

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Models for fast radiative heat transfer simulations

2. Numerical methods for radiative heat transfer
We rewrite the equation

r
E
I B

And apply Neumanns series to (formally) invert the operator

Rosseland-Approximation

1
r

2
E
B

O
(

) B

r 4 1 B
r
T r
cm m
(r , t ) k (r )
T (r , t )
t
3 0 T

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Models for fast radiative heat transfer simulations

2. Numerical methods for radiative heat transfer
Rosseland-Approximation

BUT

r 4 1 B
r
T r
cm m
(r , t ) k (r )
T (r , t )
t
3 0 T

Treats radiation as a correction of heat conductivity

Very fast and easy to implement into commercial software

packages

Only for optically thick glasses

Problems near the boundary

Standard method in glass industry

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Models for fast radiative heat transfer simulations

2. Numerical methods for radiative heat transfer
Heat transfer on a
microscale

Rosseland-Approximation

nm

Radiation = Correction of Conductivity

PN-Approximation
mm cm

Spherical Harmonic Expansion

Discrete-Ordinate-Method (FLUENT)

Heat radiation on a

ITWM-Approximation-Method

macroscale

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Models for fast radiative heat transfer simulations

2. Numerical methods for radiative heat transfer
r r
r
r
E

I
(
r
,

B
(
T
(
r
, t ), )

1
r
r
r
r

I (r , , ) E
B
(
T
(
r
, t ), )

optical thickness (small

parameter)

Neumann series

r r
r
2 r
3 r
4 r
2
3
I (r , , ) E 2 (
) 3 (
) 4 (
)4

r
... B(T ( r , t ), )

Larsen, E., Thmmes, G. and Klar, A., , Seaid, M. and Gtz, T., J. Comp. Physics 183, p. 652-675
(2002).

Thmmes,G., Radiative Heat Transfer Equations for Glass Cooling Problems: Analysis and
Numerics. PhD, University Kaiserslautern, 2002

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Models for fast radiative heat transfer simulations

2. Numerical methods for radiative heat transfer
SP1-Approximation O(4)

G G 4 B
3
2

identical to P1Approximation

SP3-Approximation O(8)

(G 2U ) G 4 B
3

2
8
9

2
U U G B
5
5
35

coupled system of
equations

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Models for fast radiative heat transfer simulations

2. Numerical methods for radiative heat transfer
Example: Cooling of a glass
plate
Parameters:
Density
Specific heat
Conductivity
Thickness
Surroundings

2200 kg/m3
900 J/kgK
1 W/Km
1.0 m
300 K

gray medium
Absorption coefficient: 1/m

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Models for fast radiative heat transfer simulations

2. Numerical methods for radiative heat transfer
Heat transfer on a
microscale

Rosseland-Approximation

nm

Radiation = Correction of Conductivity

PN-Approximation
mm cm

Spherical Harmonic Expansion

Discrete-Ordinate-Method (FLUENT)

Heat radiation on a

Full-discretization method
Klar
ITWM-Approximation-Method

macroscale

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Models for fast radiative heat transfer simulations

2. Numerical methods for radiative heat transfer
Heat transfer on a
microscale

Rosseland-Approximation

nm

Radiation = Correction of Conductivity

PN-Approximation
mm cm

Spherical Harmonic Expansion

Discrete-Ordinate-Method (FLUENT)

Heat radiation on a

Full-discretization method

ITWM-Approximation-Method

macroscale

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Models for fast radiative heat transfer simulations

2. Numerical methods for radiative heat transfer
ITWM-Approximation-Method

I k ( x, ) I k ( xb , )e k d ( x , ) k

Formal
solution:

d ( x , )

k s
k
B
(
T
(
x

))
e
ds

with

I k ( x, )

k 1

I ( x, , )d

B k (T ( x))

k 1

B(T ( x), )d
k

( ) k const. k k 1
Taylor Approximation with respect x
to

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Models for fast radiative heat transfer simulations

2. Numerical methods for radiative heat transfer
ITWM-Approximation-Method

I k ( x, ) I k ( xb , )e k d ( x , ) k

Formal
solution:

d ( x , )

k s
k
B
(
T
(
x

))
e
ds

with

I k ( x, )

k 1

I ( x, , )d

B k (T ( x))

k 1

B(T ( x), )d
k

( ) k const. k k 1

I k ( x, ) I k ( xb , )e k d ( x , ) B k (T ( x)) 1 e k d

k
1
dB

1 1 k d e k d
T ( x )
k
dT

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Models for fast radiative heat transfer simulations

2. Numerical methods for radiative heat transfer
ITWM-Approximation-Method

I k ( x, ) I k ( xb , )e k d ( x , ) k

Formal
solution:

d ( x , )

k s
k
B
(
T
(
x

))
e
ds

with

I k ( x, )

k 1

I ( x, , )d

B k (T ( x))

k 1

B(T ( x), )d
k

( ) k const. k k 1
Rosseland:

k
1
dB
I k ( x, ) B k (T ( x))
T ( x)
k dT

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Models for fast radiative heat transfer simulations

2. Numerical methods for radiative heat transfer
ITWM-Approximation-Method

I k ( x, ) I k ( xb , )e k d ( x , ) k

Formal
solution:

d ( x , )

k s
k
B
(
T
(
x

))
e
ds

with

I k ( x, )

k 1

I ( x, , )d

B k (T ( x))

k 1

B(T ( x), )d
k

( ) k const. k k 1

I k ( x, ) I k ( xb , )e k d ( x , ) B k (T ( x)) 1 e k d

k
1
dB

1 1 k d e k d
T ( x )
k
dT

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Models for fast radiative heat transfer simulations

2. Numerical methods for radiative heat transfer
Improved Diffusion Approximation

MK
1 dB k k
A T ( x, t ) k B k (T ) I k ( xb , ) e k d ( x , ) d

k 1 k dT

k 1 S 2

qr ( x)

MK
dB k

(T ) 1 e k d T ( x )d
k 1 dT
S2

MK

Ak

( ) d ( x , )
T

)
d
(
x
,

)
e

S2

In opposite to Rosseland-Approximation all geometrical information is

conserved

Lentes, F. T., Siedow, N., Glastech. Ber. Glass Sci. Technol. 72 No.6 188-196 (1999).

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Models for fast radiative heat transfer simulations

2. Numerical methods for radiative heat transfer
Improved Diffusion Approximation

MK
1 dB k k
A T ( x, t ) k B k (T ) I k ( xb , ) e k d ( x , ) d

k 1 k dT

k 1 S 2

qr ( x)

MK
dB k

(T ) 1 e k d T ( x )d
k 1 dT
S2

MK

Ak

( ) d ( x , )
T

)
d
(
x
,

)
e

S2

Correction to the heat conduction due to

radiation with anisotropic diffusion tensor

Lentes, F. T., Siedow, N., Glastech. Ber. Glass Sci. Technol. 72 No.6 188-196 (1999).

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Models for fast radiative heat transfer simulations

2. Numerical methods for radiative heat transfer
Improved Diffusion Approximation

MK
1 dB k k
A T ( x, t ) k B k (T ) I k ( xb , ) e k d ( x , ) d

k 1 k dT

k 1 S 2

qr ( x)

MK
dB k

(T ) 1 e k d T ( x )d
k 1 dT
S2

MK

Ak

( ) d ( x , )
T

)
d
(
x
,

)
e

S2

Boundary conditions
Convection term

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Models for fast radiative heat transfer simulations

2. Numerical methods for radiative heat transfer
Two Scale Asymptotic Analysis for the Improved Diffusion
Approximation

1
I (r , ) I (r , ) B (T ), r G,

I (rb , ) () I ( rb , ') (1 ()) B(Ta ), rb G, n 0

Introduce

I (r , y, ),

y G, so that I (r , ) I (r , r , )

1
r I (r , y, ) y I (r , y,
) I (r ,
) B (T )

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Models for fast radiative heat transfer simulations

2. Numerical methods for radiative heat transfer
Two Scale Asymptotic Analysis for the Improved Diffusion
Approximation

1
r I (r , y, ) y I (r , y,
) I (r ,
) B (T )

Ansatz:

1
I ( r , y , ) i I i ( r , y , )
i 0

Comparing the coefficients one obtains the Improved Diffusion

Approximation
F. Zingsheim. Numerical solution methods for radiative heat
transfer in semitransparent media. PhD, University of
Kaiserslautern, 1999

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Models for fast radiative heat transfer simulations

2. Numerical methods for radiative heat transfer
I ( x, ) I ( xb , )e
k

k d ( x , )

B (T ( x)) 1 e
k

k d

k
1
k d dB

1 1 k d e
T ( x )
k
dT

q B I d

Alternatively we use the rte

S2

MK

qr ( x) k B (T ) I ( xb , ) e
k 1

S2

k d ( x , )

dB k
d
(T ) 1 (1 k d )e k d
k 1 dT
S2
MK

T ( x )d

Formal Solution Approximation

N. Siedow, D. Lochegnies, T. Grosan, E. Romero, J. Am. Ceram. Soc., 88 [8] 2181-2187 (2005)

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Models for fast radiative heat transfer simulations

2. Numerical methods for radiative heat transfer
Example: Heating of a glass
plate
Wall T=800C

Glass
T0=200C

Parameters:
Density
kg/m3
Specific heat
J/kgK
Conductivity
Thickness

2500
1250
1 W/Km
0.005 m

Semitransparent Region:
0.01 m 7.0 m
Wall T=600C
Absorption coefficient:
0.4 /m 7136 /m (8
bands)

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Models for fast radiative heat transfer simulations

2. Numerical methods for radiative heat transfer
Example: Heating of a
glass
plate

Computational time
for 3000 time steps
Exact

81.61 s

Ida

00.69 s

Fsa

00.69 s

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Models for fast radiative heat transfer simulations

2. Numerical methods for radiative heat transfer
Example: Cooling of a glass
plate

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Models for fast radiative heat transfer simulations

2. Numerical methods for radiative heat transfer
Example:

Radiation and natural convection (FLUENT)

adiabatic

1m

T=1300
K

gravity

T=1800 K

adiabatic
5m
Radiation with diffusely reflecting gray walls in a gray
material

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Models for fast radiative heat transfer simulations

2. Numerical methods for radiative heat transfer
Example:

Radiation and natural convection (FLUENT)

Diffusely reflecting gray walls in a gray
material

40 / m

FLUENT-DOM

ITWM-UDF

>5000
Iterations

86 Iterations

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Models for fast radiative heat transfer simulations

3. Grey Absorption
The numerical solution of the radiative transfer equation is very
complex
Discretization: 60 angular
variables
10 wavelength bands
12 million unknowns
20,000 space points

Not suitable for

optimization

Development of fast numerical methods

Reduce the number of unknowns

Grey Kappa

(Find a wavelength independend absorption

coefficient?)

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Models for fast radiative heat transfer simulations

3. Grey Absorption
Klar:
averages

Problem:

Remark Frequency

many frequency bands yield many equations

Averaging the SPN equations
over frequency is possible, yields nonlinear coefficients.
as well.

POD approaches are possible

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Models for fast radiative heat transfer simulations

3. Grey Absorption
Typical absorption spectrum of
glass

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Models for fast radiative heat transfer simulations

3. Grey Absorption
One-dimensional test
example:
Thickness 0.1m
Refractive index 1.0001

Source term for heat

transfer is the divergence
of radiative flux vector

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Models for fast radiative heat transfer simulations

3. Grey Absorption
Values from literature:
Planck-mean absorption
coefficient

( ) B(T , )d
0

B(T , )d
0

Rosseland-mean absorption
coefficient

B
0 T (T , )d

1 B
0 ( ) T (T , )d

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Models for fast radiative heat transfer simulations

3. Grey Absorption
Values from literature:
Planck-mean absorption
coefficient
MK

( ) B(T , )d

MK

B (T , )d

P 55.4071m 1

Rosseland-mean absorption
coefficient
MK

MK

B
(T , )d
T

1 B
(T , )d
( ) T

R 0.4202m 1

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Models for fast radiative heat transfer simulations

3. Grey Absorption
Comparison between Planck-mean and Rosselandmean

Good approximation for

the boundary with Planck

Good approximation for

the interior with
Rosseland

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Models for fast radiative heat transfer simulations

3. Grey Absorption
The existence of the exact Grey Kappa
We integrate the radiative transfer equation with respect to the wavelength

MK

I ( x, , ) d

MK

MK

( ) I ( x, , )d ( ) B(T ( x), )d

We define an ersatz (auxiliary) equation:

J
( x, ) ( x, ) J ( x, ) ( x, ) D(T ( X )), D(T ( X ))
x
MK

If

( x, )

( ) I ( x, , ) B(T ( x), ) d

MK

I ( x, , ) B(T ( x), ) d

then

MK

B(T ( x), ) d

J ( x, )

MK

I ( x, , ) d

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Models for fast radiative heat transfer simulations

3. Grey Absorption
The existence of the exact Grey Kappa

( x, )

MK

( ) I ( x, , ) B(T ( x), ) d

MK

I ( x, , ) B(T ( x), ) d

The Grey Kappa is not depending on wavelength BUT on position and direction
The Grey Kappa can be calculated, if we know the solution of the rte
How to approximate the
intensity?

AND

How to get rid of the direction?

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Models for fast radiative heat transfer simulations

3. Grey Absorption
MK

( x, )

( ) I ( x, , ) B(T ( x), ) d

MK

I ( x, , ) B(T ( x), ) d

How to approximate the intensity?

We use once more the formal solution

I ( x, , ) 1 e ( ) d ( x, ) B(T , )

dT
dB
1 1 ( ) d ( x, ) e ( ) d ( x, )
( x)
(T , ) ...
( )
dx
dT

How to get rid of direction?

x
0 xl/2
lx l/2 x l

d ( x, ) h( x )

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Models for fast radiative heat transfer simulations

3. Grey Absorption
New (approximated) grey kappa can be formulated as

%
( x, T ) P (T )G1 ( x) R (T )G2 ( x) Planck-RosselandSuperposition

MK

( ) B(T

ref

, )e ( ) h ( x ) d

G1 ( x)

P (Tref )

MK

( ) h ( x )

B (Tref , )e

d 0 : G1 ( x) 1 G2 ( x) 0
d : G1 ( x) 0 G2 ( x) 1

a
dB
1 1 ( )h( x) e ( ) h ( x )
(Tref , ) d
( )
dT

Planck-mean value
Rosseland-mean value

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Models for fast radiative heat transfer simulations

3. Grey Absorption
Example of a 0.1m tick glass plate with initial temperature
1500C

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Models for fast radiative heat transfer simulations

3. Grey Absorption
Example of a 0.1m tick glass plate with initial temperature
1500C

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Models for fast radiative heat transfer simulations

3. Grey Absorption
Summary:
For the test examples the Planck-Rosseland-Superposition mean value
gives the best results
For the optically thin case:
For the optically thick case:

PRS
PRS

Planck
Rosseland

PRS ( x, T ) P (T )G1 ( x) R (T )G2 ( x)

Stored for different

temperatures in a
table

Calculated in
advanced

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Models for fast radiative heat transfer simulations

3. Grey Absorption
Summary:
For the test examples the Planck-Rosseland-Superposition mean value
gives the best results
For the optically thin case:
For the optically thick case:

PRS
PRS

Planck
Rosseland

These are ideas! Further research is needed!

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Models for fast radiative heat transfer simulations

4. Application to flat glass tempering

Wrong cooling of glass and glass

products causes large thermal stresses

Undesired crack

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Models for fast radiative heat transfer simulations

4. Application to flat glass tempering
Thermal tempering consists
of:

1.

Heating of the glass at a temperature

higher the transition temperature

2.

Very rapid cooling by an air jet

Better mechanical and thermal
strengthening to the glass by way
of the residual stresses generated
along the thickness

N. Siedow, D. Lochegnies, T. Grosan, E. Romero, J. Am. Ceram. Soc., 88 [8] 2181-2187 (2005)

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Models for fast radiative heat transfer simulations

4. Application to flat glass tempering
Cooling of the glass melt depends on the temperature distribution in time
and space
Characteristically for
No fixed point where glass changes from fluid
glass:
to solid state
There exists a temperature range
The essential property is the viscosity of the
glass
low

high

high viscosity

low viscosity

Linear-elastic material

Newtonian fluid

temperatur
e

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Models for fast radiative heat transfer simulations

4. Application to flat glass tempering
Viscosity changes the density depending on the temperature
Change in density (structural relaxation) influences the stress inside the
glass
A numerical model for the calculation of transient and residual stresses in
glass during cooling, including both structural relaxation and viscous
stress relaxation, has been developed by Narayanaswamy und Tool
Commercial software packages like ANSYS and ABAQUS have
implemented this model

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Models for fast radiative heat transfer simulations

4. Application to flat glass tempering

N. Siedow, D. Lochegnies, T. Grosan, E. Romero, J. Am. Ceram. Soc., 88 [8] 2181-2187 (2005)

ITWM model gives the closest result for temperature

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Models for fast radiative heat transfer simulations

4. Application to flat glass tempering

N. Siedow, D. Lochegnies, T. Grosan, E. Romero, J. Am. Ceram. Soc., 88 [8] 2181-2187 (2005)

CPU time in s:

ITWM model comparable with

Rosseland and much faster than
exact solution model
Rosseland gives the worst surface and
mid-plan temperature difference

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Models for fast radiative heat transfer simulations

4. Application to flat glass tempering

N. Siedow, D. Lochegnies, T. Grosan, E. Romero, J. Am. Ceram. Soc., 88 [8] 2181-2187 (2005)

ITWM model gives the closest result for transient and residual
stresses

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Models for fast radiative heat transfer simulations

4. Application to flat glass tempering

Production of bodies, like cubes,

cylinders, angles (Kipferl), .
Special products by postprocessing (grinding) of these
simple geometrical pieces
Deformation after cooling

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Models for fast radiative heat transfer simulations

5. Application to flat glass tempering

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Models for fast radiative heat transfer simulations

5. Conclusions
1. Temperature is one of the main parameters to make good glasses
2. To simulate the temperature behavior of glass radiation must be
taken into account
3. One needs good numerics to solve practical relevant radiative
transfer problems - Improved Diffusion Approximation methods
are alternative approaches for simulating the temperature behavior
in glass
4. A grey absorption coefficient can save CPU time
5. The right temperature profile is necessary to simulate stresses during glass
cooling

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Glass 61