Then, with the size of grate fixed and the most efficient burning of the fuel arranged for, the capacity of the furnace depends simply on increasing the area of the hearth to as great an extent as the heat generated is capable of maintaining at the desired temperature.
The breadth of the furnace is however, limited by—
- (a) The span of arch which can be supported in the construction.
- (b) The length of the tools which can be conveniently managed.
The maximum width so far found satisfactory is about 19 feet, so that this dimension being fixed, the furnace capacity is enlarged by increasing the length, and this is limited only by the distance from the fire-box to which the flame can maintain the temperature necessary for keeping the charge in a state of perfect fluidity. For many years the length was regarded as limited to 50 feet, smelting about 2·7 to 3·0 tons of charge per ton of coal, but E. P. Mathewson, at Anaconda, finding the escaping gases still very hot, gradually increased the length of the hearth, first to 60 feet, then to 80 feet, and finally up to 116 feet, when the furnace smelted 4·83 to 5·0 tons of charge per ton of coal. The gases then left the furnace at a temperature of about 950° C., and contained sufficient heat to fire two Stirling boilers, each of 375 H.P. Every furnace thus provided about 600 H.P. from this waste heat, and the gases finally escaped at a temperature of 320° C.
Fig. 23.—Development of the Reverberatory Furnace (Gowland).
The capacity of these large furnaces is about 270 to 300 tons of charge per day, and in addition to the economy and efficiency resulting from the treatment of such large quantities of material at once, there are the further great advantages in that—
- (a) Settling of matte and slag is much more perfect when such large quantities of fluid material are stored.
- (b) Tapping of matte and slag is easier and more efficiently conducted.
About 110 feet appears to be the practicable maximum for furnace length, and reverberatories of this size are being constructed wherever circumstances permit, several new smelters having erected such furnaces—there are eight at Anaconda, Mont.; two at Garfield, Utah; five at Tooele, Utah; four at Cananea, etc. The length of the hearth is naturally dependent upon the character of the fuel, particularly the length of flame given out on burning. Bituminous fat coals are the most suitable for this purpose, and in localities where such fuel is not available, the use of liquid fuel has now been successfully adopted.