Then the master breaks out the whole of the mouth of the furnace with a crowbar, and with that other hooked bar, the rabble and the five-toothed rake, he extracts the accretions and the charcoal. This crowbar is not unlike the other hooked one, but larger and wider; the handle of the rabble is six feet long and is half of iron and half of wood. The furnace having cooled, the master chips off the accretions clinging to the walls with a rectangular spatula six digits long, a palm broad, and sharp on the front edge; it has a round handle four feet long, half of it being of iron and half of wood. This is the first method of smelting ores.
Because they generally consist of unequal constituents, some of which melt rapidly and others slowly, the ores rich in gold and silver cannot be smelted as rapidly or as easily by the other methods as they can by the first method, for three important reasons. The first reason is that, as often as the closed tap-hole of the furnace is opened with a tapping-bar, so often can the smelter observe whether the ore is melting too quickly or too slowly, or whether it is flaming in scattered bits, and not uniting in one mass; in the first case the ore is smelting too slowly and not without great expense; in the second case the metal mixes with the slag which flows out of the furnace into the forehearth, wherefore there is the expense of melting it again; in the third case, the metal is consumed by the violence of the fire. Each of these evils has its remedy; if the ore melts slowly or does not come together, it is necessary to add some amount of fluxes which melt the ore; or if they melt too readily, to decrease the amount.
The second reason is that each time that the furnace is opened with a tapping-bar, it flows out into the forehearth, and the smelter is able to test the alloy of gold and lead or of silver with lead, which is called stannum.[16] When the tap-hole is opened the second or third time, this test shows us whether the alloy of gold or silver has become richer, or whether the lead is too debilitated and wanting in strength to absorb any more gold or silver. If it has become richer, some portion of lead added to it should renew its strength; if it has not become richer, it is poured out of the forehearth that it may be replaced with fresh lead.
The third reason is that if the tap-hole of the furnace is always open when the ore and other things are being smelted, the fluxes, which are easily melted, run out of the furnace before the rich gold and silver ores, for these are sometimes of a kind that oppose and resist melting by the fire for a longer period. It follows in this case, that some part of the ore is either consumed or is mixed with the accretions, and as a result little lumps of ore not yet melted are now and then found in the accretions. Therefore when these ores are being smelted, the tap-hole of the furnace should be closed for a time, as it is necessary to heat and mix the ore and the fluxes at the same time; since the fluxes fuse more rapidly than the ore, when the molten fluxes are held in the furnace, they thus melt the ore which does not readily fuse or mix with the lead. The lead absorbs the gold or silver, just as tin or lead when melted in the forehearth absorbs the other unmelted metal which has been thrown into it. But if the molten matter is poured upon that which is not molten, it runs off on all sides and consequently does not melt it. It follows from all this that ores rich in gold or silver, when put into a furnace with its tap-hole always open, cannot for that reason be smelted so successfully as in one where the tap-hole is closed for a time, so that during this time the ore may be melted by the molten fluxes. Afterward, when the tap-hole has been opened, they flow into the forehearth and mix there with the molten lead. This method of smelting the ores is used by us and by the Bohemians.
The smelter, besides lead and cognate things, uses fluxes which combine with the ore, of which I gave a sufficient account in [Book VII]. The metals which are melted from ores that fuse readily in the fire, are profitable because they are smelted in a short time, while those which are difficult to fuse are not as profitable, because they take a long time. When fluxes remain in the furnace and do not melt, they are not suitable; for this reason, accretions and slags are the most convenient for smelting, because they melt quickly. It is necessary to have an industrious and experienced smelter, who in the first place takes care not to put into the furnace more ores mixed with fluxes than it can accommodate.
The powder out of which this furnace hearth and the adjoining forehearth and the dipping-pot are usually made, consists mostly of equal proportions of charcoal dust and of earth, or of equal parts of the same and of ashes. When the hearth of the furnace is prepared, a rod that will reach to the forehearth is put into it, higher up if the ore to be smelted readily fuses, and lower down if it fuses with difficulty. When the dipping-pot and forehearth are finished, the rod is drawn out of the furnace so that the tap-hole is open, and through it the molten material flows continuously into the forehearth, which should be very near the furnace in order that it may keep very hot and the alloy thus be made purer. If the ore to be smelted does not melt easily, the hearth of the furnace must not be made too sloping, lest the molten fluxes should run down into the forehearth before the ore is smelted, and the metal thus remain in the accretions on the sides of the furnace. The smelter must not ram the hearth so much that it becomes too hard, nor make the mistake of ramming the lower part of the mouth to make it hard, for it could not breathe[17], nor could the molten matter flow freely out of the furnace. The ore which does not readily melt is thrown as much as possible to the back of the furnace, and toward that part where the fire burns very fiercely, so that it may be smelted longer. In this way the smelter may direct it whither he wills. Only when it glows at the part near the bellows' nozzle does it signify that all the ore is smelted which has been thrown to the side of the furnace in which the nozzles are placed. If the ore is easily melted, one or two wicker baskets full are thrown into the front part of the furnace so that the fire, being driven back by it, may also smelt the ore and the sows that form round about the nozzles of the bellows. This process of smelting is very ancient among the Tyrolese[18], but not so old among the Bohemians.
