Within a half hour after the current is turned on a gas begins to be
emitted from the sides and top of the furnace, and when a match is
applied to it, it lights and burns with a bluish flame during the whole
process. It is estimated that over five and one-half tons of this gas
is thrown off during the burning of a single furnace. This gas is called
carbon monoxide, and is caused by the carbon of the coke uniting with
the oxygen of the sand. When we consider the vast amount of material
that comes away from the furnace in the form of gas it is easy to see
why it is necessary to introduce sawdust or some equivalent material
into the mixture, in order to give the whole bulk porosity, so that the
gas can readily escape. We should also expect that after five and
one-half tons had been taken away from the whole bulk that it would
shrink in size. This is found to be the case. The top of the mass of
material sinks down to a considerable extent by the end of the time it
has been exposed to this intense heat. Gradually, after the current has
been turned on, the core becomes heated, first to a red, and afterwards
to an intense white heat. This heat is communicated to the material
surrounding the core, producing various effects in the different strata,
owing to the fact that it is not possible to keep a uniform heat
throughout the whole bulk of material. Some of it will be "overdone" and
some of it "underdone." The material which lies immediately in contact
with the core will be overheated, and that, which at one stage was
carborundum, has become disintegrated by overheating.
The silica of the compound has been driven off, leaving a shell of
graphitic substance formed from the coke.
After the current is shut off and the furnace has cooled down, a
cross-section through the whole mass becomes a very interesting study.
The core itself, owing to the intense heat it has been subjected to, has
had the impurities driven out of the coke, leaving a substance like
black lead, that will make a mark like a lead-pencil, and is really the
same substance, known as plumbago, in one of its forms. It is the carbon
left after the impurities have been driven out of the coke. Surrounding
the core for a distance of ten or twelve inches, radiating in every
direction, beautifully colored crystals of carborundum are found, so
that a single furnace will yield over 4000 pounds of this material.
Beyond this point the heat has not been great enough to cause the union
between the carbon and silica, which leaves a stratum of partly-formed
carborundum; outside of that the mixture is found to be unchanged.
Public-domain text, read in full here on John Shaqi.
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