(vii.) There is effected an enormous saving of time, fuel, and labour by maintaining a constant high temperature, instead of having to heat the furnace up again after each tapping and charging, as was the case with the older methods of working.

(viii.) The levelling of the charges in the furnace is greatly facilitated. The charges would otherwise pile up under the charging hoppers, and form heaps which are not only difficult to melt down, but which tend to stick to the furnace bottom, requiring time and arduous labour for their removal. In modern practice, charges in quantities of 10 to 15 tons at a time maybe dropped in, these merely spread themselves out on the bath of molten material and float down in a thin stream towards the skimming door at the end, and they generally melt and disappear when half-way down the furnace.

By this means, the working doors at the side need practically never be opened for manipulating the fresh charges.

5. The Charging of Hot Calcines.—This improvement was also introduced by Pearse, and possesses very many advantages; he was able to increase the furnace output by 23 per cent. with the aid of this device.

Instead of allowing the materials from the roasters to cool down, they are taken straight from the roaster bins to the hoppers which feed the reverberatory furnace, where they retain much of their heat until charged into the furnace, being then still red hot as a rule. Much time and fuel is thus saved owing to the charge requiring less heating up, and the cooling action of charging is diminished.

A charge of 15 tons is completely melted within an hour.

6. Regulation of Furnace by Draft Pressure.—It has already been pointed out that rapid combustion of fuel, and consequently rapid melting, is greatly assisted by good draft through the furnace. In modern practice, where the factors, such as charge composition, nature of fuel, and furnace proportions, have been satisfactorily arranged for independently, the actual working of the furnace is regulated by the draft pressures. These are registered automatically by water-manometers arranged at various points. One usually communicates with the furnace, above the fire-bridge; another is connected to the down-take flues. The indications of these instruments enable a record to be kept of the various operations, and of the charging of the furnace, as well as of the condition of the fire. The usual draft pressure worked with corresponds to about 0·8 inch of water, registered above the fire-bridge.

On opening the hopper for charging, the pressure drops almost to zero; the opening of any doors causes a reduction in pressure; the charging of coal is also rendered noticeable by a drop in the record. Reduction of pressure also indicates “airing” of the furnace by an excess of air entering through channels in the bed of coal; draft-pressure thus acting as a check on the firing and also on the grating, since the formation of excessive clinker in the fire-box is indicated by an increase in the pressure.

Corresponding to such record over an 8-hour shift, as shown on fig. 24, Offerhaus noted the following furnace manipulations, illustrating how accurately the operations are checked by this method:—

a.m.
7.00–7.14Skimming (coal charged during this period).
7.16–7.16½Side door opened.
7.28–7.31Coal charged.
7.52–7.57Charged.
8.05–8.15Tapped.
8.15Coal charged.
8.40Coal charged.
8.54–8.59Grating.
9.05Side door opened. Charged.
9.27Coal charged.
9.49Coal charged.
10.07Charged.
10.25Coal charged.
10.41Coal charged.
10.45–10.58Skimming.
11.04Coal charged.
11.16Charged.
11.16–11.35Some grating.
11.36Coal charged.
12.03 p.m.Coal charged.
12.04Charged.
12.37–12.48½Tapped, 1½ ladles (about 11 tons).
12.45Coal charged.
1.00Charged.
1.11–1.45Grating.
1.26Coal charged.
1.44Charged.
1.51Coal charged.
2.18Coal charged.
Total charges during shift,16 coal, 7 calcines.