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A concept of two-stage melting was proposed in order to design an efficient furnace, in which the melting process was strictly divided into two-stages; rough melting and refining. The melt down characteristics were studied using a 40l pot set in a gasfired furnace, and the behavior of sodium sulfate in the two-stage process was simulated using a 300ml platinum crucible in electric furnaces. The thickness of foam layer was found to be determined by the amount of SO3 released from the melt during the refining process. The number of residual sand grains was found to depend not only on the melting time but also on the intensity of agitation of the melt by the released SO3. The number of bubbles was found to be determined mainly by the amount of SO3 retained in the melt at the end of the refining process. The following conclusions were derived for rough melting and refining processes, respectively. (1) The condition of rough melting can be determined mainly by the melt down rate, for which relatively low temperature (1250°-1400°C) is sufficient. For effective refining, the rough melting should be conducted below the decomposition temperature of Na2SO4 (1450°C), so that the content of SO3 in the melt might be kept at a proper level at the end of the rough melting. The rough melting time should be between one and two hours for effective refining. (2) The refining temperature should be above the decomposition temperature of Na2SO4 to remove bubbles in the melt effectively.

Decomposition Behavior of Sodium Sulfate in Two-Stage Melting Process (Rough Melting and Refining) for Manufacturing of Sheet Glass