For most purposes of glass-making, such as the production of sheet
and plate-glass of all kinds, the alkali is introduced in the form
of salt-cake--_i.e._, sulphate of soda. This product is obtained
as the result of the first step of the Le Blanc process of alkali
manufacture--_i.e._, by the action of sulphuric acid on sodium
chloride; salt-cake is thus a relatively crude product, and its use
is due to the fact that it is by far the cheapest source of alkali
available for glass-making. There are, however, certain disadvantages
connected with its use. The chief of these is the fact that silica
cannot decompose salt-cake without the aid of a reducing agent; such a
reducing agent is partly supplied by the flame-gases in the atmosphere
of the furnace, but in addition to these a certain proportion of
carbon, in the form of coke, charcoal or anthracite coal must be added
to all glass mixtures containing salt-cake. The use of a slightly
incorrect quantity of carbon for this purpose leads to disastrous
results, while even under the best conditions it is not easy to remove
all traces of sulphur compounds from glass made in this way. A further
risk of trouble arises in connection with salt-cake from the fact that
it is never entirely free from more or less deleterious impurities.
According to the exact manner in which it has been prepared, the
substance always contains a small excess either of undecomposed sodium
chloride or of free sulphuric acid, or the latter may be present in the
form of sulphate of lime. A good salt-cake, however, should contain
at least 97 per cent. of anhydrous sodium sulphate, and not more than
1·0 per cent. of either sodium chloride or sulphuric acid. While pure
sodium sulphate is readily soluble in water, ordinary salt-cake always
leaves an insoluble residue, consisting frequently of minute particles
of clay or other material derived from the lining of the furnace in
which it was prepared, or from the tools with which it was handled;
and these impurities are liable to become deleterious to the glass if
present in any quantity. The insoluble residue should not exceed 0·5
per cent. in amount, and in the best salt-cake is generally under 0·2
per cent.
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