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Silcarb:- The Reverberatory Furnace

The copper that arrived in the smelter was anywhere from 70 to 90 percent pure. Due to the unique nature of Lake Superior copper, most of those impurities manifested themselves as pieces of foreign rock embedded within the copper itself. As a result, Copper Country smelters – including the Quincy Smelting Works – utilized a rather uncomplicated procedure to purify their copper wares. A process that essentially boiled down to melting the copper and skimming off its impurities. The central piece of equipment used during this process was the reverberatory furnace.


A reverberatory furnace consisted of a large brick-lined pot – known as a hearth – in which the copper was melted down to a liquid. This was done not with direct heat, but with reflected – or reverberated – heat emanating from an adjacent firebox. The natural draft created by the furnace’s chimney would pull the hot gases from the firebox up across the specially curved top of the hearth before being pulled up the flue. Along the way those hot gasses would reverberate off the roof and bounce down into the copper filled hearth – slowly melting it.

While rather simple in its aggregate, the actually reverberatory process actually involved several procedures and nearly a full day before copper could be poured into waiting ingots. The first of these steps was to load the copper into the furnace in a process known as “charging”.


During the charging process the furnace’s firebox is doused and its doors and top are opened. While copper could have been loaded into the furnace from any of these side doors, most of the mineral was loaded from the top – thanks to the furnace’s removable top. The furnace is first filled with the smaller pieces of copper to create a carpet of mineral along the furnace’s bottom. Then the larger pieces – mass copper – are placed on top of that copper carpet. After the furnace reaches is maximum load – about 36,000 pounds – its top is dropped back in place and all the doors are closed.


With the furnace charged it was now time to ignite the firebox and beginning the heating process. A layer of coal was placed in the firebox atop a metal grate spanning across the ash pit and lit on fire. The fire is fed by air drafting up through the open ash pit, air that is forced through the grate and directly across the hot coals before its drafted over to the hearth and up the flue.

After a few hours in the furnace, the copper and rock will begin to melt and the next step of the process can commence. Due to the differences in density between copper and the rock that surrounds it, the molten contents of the hearth began to separate naturally into two distinct layers. At the bottom is the copper itself – known as the matte – while floating on top forms a layer of molten rock known as slag. Once formed, this slag would be skimmed off the top of the copper and removed through the furnace door. Skimming would continue for another 12-15 hours until all the remaining copper is thoroughly melted and all the slag that forms is removed.

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