Influence of energy distribution, melting temperature, kinetics and space geometry on glass melting efficiency

•Effect of melting factors on glass melting performance was investigated.•Space utilization was identified as a crucial quantity of melting efficiency.•Mathematical simulation was used as a tool of investigation.•Novel formula of melting performance was derived and verified.•Extreme melting conditions were discussed and schema of melting depicted. The role of melting phenomena such as batch conversion, sand dissolution, bubble removal, and character of melt flow in glass melting process was investigated by using mathematical modeling. The objective of simulations was to achieve highest melting performance of a model “T-space”. Depending on the energetic factors, which express the longitudinal energy distribution and the proportion between Joule and combustion energy, uniform or spiral flow in the melting space were adjusted, characterized by high melting performance and reduced specific energy consumption. The effects of other factors, such as temperature, bubble growth rate, thickness of batch layer, and space geometry were investigated and their complex role in melting process discussed. Semiempirical formula expressing the relation between melting phenomena was derived. A schema illustrating the phenomena roles in melting process was designed.