Glass Salt

Diderot, d'Alembert, L'Encyclopédie (1772) Raking Out Roasted Frit

Making glass from raw materials involves several steps. In his 1612 book on glassmaking, L'Arte Vetraria, Antonio Neri breaks the process down into parts so that, "given a bit of experience and practice, as long as you do not purposely foul-up, it will be impossible to fail." Pure white sand, or preferably quartz river stones which Neri calls "tarso" is broken up and pulverized into a fine powder. The initial work can be done by heating the stones in a furnace, then dropping them into a vat of clean cold water, where they will fracture due to the thermal shock. The process was often repeated multiple times. From there, the pieces are pulverized in a stone mortar and pestle. Stone, because metal tools would contaminate the quartz, and in the end tint the glass. Finally, a powder is obtained by grinding with a stone tool on a flat granite "porphyry stone." This powdered quartz is the main ingredient of glass.

The second critical ingredient is the flux, what Neri calls "glass salt" or "soda." This can be obtained from mineral sources, but European glassmakers in the seventeenth century extracted all their salt from certain plants. The powdered quartz was mixed with the salt and a third ingredient, which is critical, lime. Lime is simply calcium oxide used by builders to make cement. It is nothing more than pulverized seashells roasted to a high temperature. Neri advises using two pounds of lime for every hundred pounds of salt. He specifies that it should be added to all his frit recipes, but it is not clear that he understood its critical importance; without lime, the glass would be subject to attack by mere water, eventually decomposing. This mixture of soda, lime and silica when heated in a kiln would chemically react forming "frit." The combined materials were raked around in a kiln for a long period (many hours) and finally formed nut sized pieces. It was cooled and heaped into piles in dry cellars where it was aged for a time. This is where some real "magic" in glassmaking takes place. The glass salt or soda dramatically lowers the melting temperature of the quartz, all the way down to a point that was easily achieved in a wood fired furnace. When a batch of glass was made, the aged frit was then melted in furnace crucibles and skimmed to remove excess salt, which floated on the surface; it could foul the glass, and smelled terrible. The melted glass, now ready to work, was sometimes colored and finally made into objects by gaffers. 

Neri obtained his glass salt from products shipped by traders from the Levant (eastern Mediterranean). It was supplied as the dried, partially charred remains of special plants that grow in arid seaside conditions. Shipping them this way cut down on weight and volume, and prevented rotting. These Soda and Kali plants contain large amounts of sodium carbonates. This is a white powder, chemically identical to what we know as "washing soda." He advises, 

In buying either of these make sure it is richly salted. This may be determined by touching it with the tongue in order to taste its saltiness; but the surest way of all is to do a test in a crucible and to see if it contains much sand or stones, a thing common in this art and very well known by glass conciatori.

He crushes any large pieces of the product in a stone mortar, and sifts the result through a fine screen, ensuring that most of what remains is salt.  

As the common proverb of the art of glassmaking says: a fine sieve and dry wood bring honor to the furnace. Then with any of these sodas, 100 pounds of soda ordinarily requires 85 to 90 pounds of tarso.

Neri sets up large cauldrons of clean water over brickwork stoves, adds the plant product and boils the water. He strains the insoluble parts out and reduces the liquid by evaporation until crystals of the salt start to form on the surface. He skims these off and continues the process. Finally he carefully dries the product. Our glassmaker describes several variations of this process, including one in which he takes extreme measures to ensure the purity of the salt and clarity of the finished glass. In all, this is a task that could easily take several weeks to perform for the amount of frit to fill a single pot for the gaffer to work.

Not content with the established materials, our glassmaker experimented extensively with other plants: 

[U]se the husks and stalks of fava beans after the farmhands have thrashed and shelled them. With the rules and diligence prescribed for the Levantine polverino salt, extract the salt from this ash, which will be marvelous, and from which a frit can be made using well-sifted white tarso, as is described throughout this work. A very noble frit will result, which in the crucible will make a crystal of all beauty. The same may be made from the ashes of cabbages, or a thorn bush that bears small fruit, called the blackberry, even from millet, rush, marsh reeds, and from many other plants that will relinquish their salt. *

*These other plants produce potassium carbonate salts with similar properties to sodium carbonate.

** This post first appeared here 9 December 2013.