The fine art of the process seems to be the exact combination of
temperature, time, and stirring, suitable for each composition of the
glass. There are, too, losses by volatilization during melting, and
even afterwards, that must be reckoned with in the proportions of the
various materials put into the melting, and in the temperatures reached
and maintained.
One cannot deduce accurately the percentage mixture of the raw
materials from an analysis of the glass, and it is notorious that the
product even of the best manufacturers not infrequently fails to run
quite true to type. Therefore the optical properties of each melting
have carefully to be ascertained, and the product listed either as a
very slight variant from its standard type, or as an odd lot, useful,
but quite special in properties. Some of these odd meltings in fact
have optical peculiarities the regular reproduction of which would be
very desirable.
The purity of the materials is of the utmost importance in producing
high grade glass for optical or other purposes. The silica is usually
introduced in the form of the purest of white sand carrying only a few
hundredths of one per cent of impurities in the way of iron, alumina
and alkali. The ordinary alkalis go in preferably as carbonates, which
can be obtained of great purity; although in most commercial glass the
soda is used in the form of “salt-cake,” crude sodium sulphate.
Calcium, magnesium, and barium generally enter the melt as carbonates,
zinc and lead as oxides. Alumina, like iron, is generally an impurity
derived from felspar in the sand, but occasionally enters intentionally
as pure natural felspar, or as chemically prepared hydrate. A few
glasses contain a minute amount of arsenic, generally used in the
form of arsenious acid, and still more rarely other elements enter,
ordinarily as oxides.
Whatever the materials, they are commonly rather fine ground and very
thoroughly mixed, preferably by machinery, before going into the
furnaces. Glass furnaces are in these days commonly gas fired, and
fall into two general classes, those in which the charge is melted
in a huge tank above which the gas flames play, and those in which
the charge is placed in crucibles or pots open or nearly closed,
directly heated by the gas. In the tank furnaces the production is
substantially continuous, the active melting taking place at one end,
where the materials are introduced, while the clear molten glass flows
to the cooler end of the tank or to a cooler compartment, whence it is
withdrawn for working.
The ordinary method of making optical glass is by a modification of
the pot process, each pot being fired separately to permit better
regulation of the temperature.
The pots themselves are of the purest of fire clay, of moderate
capacity, half a ton or so, and arched over to protect the contents
from the direct play of the gases, leaving a side opening sufficient
for charging and stirring.
Public-domain text, read in full here on John Shaqi.
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