Assuming that the materials are available in a suitable state of
fineness, the first step in the process of glass melting consists
in securing their admixture in the proper proportions. This may be
done by hand entirely, by hand aided by some machinery, or entirely
automatically. The process of hand mixing is only available for
relatively small quantities of material and requires very careful
supervision if inadequate mixing is to be avoided. In most cases the
actual weighing out is done by hand, while the mixing is done by
machinery. In this process the separate ingredients are weighed out
from barrows or skips and are tipped into a large hopper whence each
batch, as soon as it is completed, passes into the mixing chamber
of the mixing machine. This may consist of nothing more than a
cylindrical chamber in which steel arms revolve and stir up the
contents, but more modern appliances take the form of rotating barrels
or cylinders, set up on an inclined axis and provided with suitable
shelves and baffles; in these the materials are very thoroughly shaken
over and mixed. Where hand mixing is adopted, the various ingredients
of each batch are thrown into a large bin and are there turned over
several times with shovels, the entire material being ultimately sieved
through a wire sieve of suitable mesh. In all cases the resulting
mixture should be perfectly uniform in colour and texture, and analyses
of different samples should show only small variations. With the
mixture thus prepared the “cullet” or broken glass which is to be
re-melted is now incorporated; ideally this should also be uniformly
distributed, but this is rarely attempted in practice on the large
scale.
The next step in the process is the introduction of the mixture into
the furnace. In the case of tank furnaces this is a simple matter,
since in these the temperature is kept as nearly constant as possible,
and raw materials may, therefore, be introduced at almost any time,
the amount introduced being so regulated as to keep the level of the
molten glass or “metal” as nearly constant as possible. The actual
introduction is managed by means of a large opening or door at what is
known as the “melting end” of the furnace. Normally this opening is
covered by a large fire-brick block suspended by a chain running over
pulleys and counterbalanced by a counterpoise weight. When charging
is to begin, this block is raised and the opening is uncovered. The
raw materials are then introduced either by hand, by the aid of
long-handled shovels, or they are first filled into a long scoop
moved by mechanical means forward into the furnace, where it is given
a half-turn, which empties the contents out, and is then rapidly
withdrawn.
This charging process may be repeated every half-hour, or larger
quantities may be introduced once every four hours, according to the
practice that may be adopted at any particular furnace.
Public-domain text, read in full here on John Shaqi.
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