I finally got a hold of some coal last week, and spent my Saturday melting copper with several friends. We took lots of pictures and video, so this should be an interesting (and lengthy) post. All images link to bigger versions.
We got to my house about 9:30am. Typically, firing the furnace is an evening endeavor, but this time we started early because two of the guys, Mike and Ben, brought about 45 pounds of copper. We figured it would take at least a whole day to melt it all. Also, the furnace hadn't been used since last spring, so there was a lot of work to do to get it in shape to light.

The furnace before we started.
A toad we found living inside. We put him near a tree, away from the fire.

This is the hole we found the toad in. It is the entrance for the bellows.

The copper we set out to melt.
The furnace is constructed to allow air to be forced up through the bottom to make the coal burn hotter. The hollow part at the bottom fills up with ash, and has to be cleaned out before every firing. Typically, several bricks have to be replaced as well. Since I just use cheap Wal-mart brick, they melt away after one or two sessions. A lot also crack from the heat, and cracked bricks make the furnace unstable and allow heat to escape. After rebuilding the furnace, we put pea gravel around the sides to help insulate and seal it. The seal serves two important functions. The first is to keep air in. The second is to keep hot coals from dangerously flying out.
Once complete, we add the bellows. This device is a modified bathroom vent fan. We originally used a leaf blower, but the leaf blower moves too much air and causes the coal to burn too hot and too fast. It also has no flow regulator. The vent fan moves much less air, but still enough to make the coal burn hot. It also has an opening that can be adjusted to regulate the air flow, allowing for even more control over the temperature. The bellows ducting is also sealed with pea gravel.
Starting the furnace has been hit-or-miss in the past. Coal can't be lit directly, so we have to step up from newspaper to sticks to coal. Sometimes it doesn't catch right away, but Saturday it fired up on the first try. Once lit, we allowed the bellows to run at full blast for several minutes to heat up the fuel, the furnace, and the crucible. This process drives off moisture, which can cause problems like cracking and explosions.
Starting the fire. Coal is filthy and stinky.

The fire is now hot. (Actually this was taken late in the afternoon.)
We started the melting process with some finely-divided pieces of copper. Small pieces melt faster than larger pieces because they have a larger surface area and contact more of the crucible, which helps conduct heat faster. Once a pool of molten copper is present in the bottom of the crucible, it gets much easier to melt larger pieces just by submerging them in the liquid. The melting process takes a long time, but once we have enough molten copper, we pour.

The small pieces of copper we melted first.
Pouring is a dangerous process. It involves getting close to and moving about ten pounds of 2500° F material. And it's liquid, so if it spills on you, you get covered with it. I once poured some copper into a wet mold. The water boiled instantly and flung blobs of molten copper all over the place. It missed everyone, fortunately. Ever since then, I've been wearing pants, sweatshirts, gloves, and a face mask to pour. They provide the additional benefit of acting as a heat shield, so I don't burn my hands up while pouring. The crucible tongs may look long, but the heat radiating off the crucible is astounding. Our pouring operation was pretty well-coordinated. We typically had one or two men filming, one covering the mold, and one standing by to add fuel to the furnace and operate the fire hose if something went wrong.

This copper is just about ready to pour.
Me pouring. I forgot my gloves...
A brand new (and very hot) copper ingot.
Pouring again. I had gloves this time.
An action shot of the pour.
About 3 o'clock, we went in to town to eat and buy new bricks. Some of the bricks at the top of the furnace were cracking, making it difficult to seal the top of the furnace. The fragments were also getting in the way of refueling. We bought some broken concrete landscaping stones at Walmart. We only paid half price because they were broken, but we still got ripped off. Oh well, they held up pretty well for the rest of the day. We then went to Pizza Hut. Two interesting things happened there. First, the waitress asked what we had been up to that afternoon, and got the unexpected answer of "melting copper in [my] back yard." Second was the only injury of the day. One of the guys chipped his tooth on a fork. He was eating his pizza with a fork (yes) because his hands were dirty from the coal.
When we rebuilt the furnace, we built it higher than before. It proved to be a big engineering mistake. We had the bellows running full-blast, but the copper wouldn't melt at all. Turns out the extra space between the crucible/fuel and the top of the furnace allowed the heat to escape easily. After taking the brick down a level, things started working again.

A night shot of the flames coming out the top of the furnace.
The first several bars we poured came out kind of lumpy on top. We eventually figured out that the molds were too cold and were causing the copper to freeze to quickly. Once we started heating the molds to about 1000° F, the copper cooled properly and made the top nice and smooth. In the 10 hours we were outside, we only melted about half of all the copper...maybe less. But now that we know more about controlling the temperature and pouring the copper properly, we think we can go through the rest pretty quickly some weekend. We'll probably wait until it gets much cooler. Standing next to the furnace in 85°+ weather is miserable. Wearing pants, sweatshirts, and gloves is even more miserable. There will certainly be another post when we melt again.
The steel plate covering the furnace got so hot it was glowing. It's very cool at night.
From left to right: Josh Gevirtz, Ben Behnkendorf, Mike Broom, Alex Corn, and Ryan Wampler.
The photos above were not all taken by me. In fact, most weren't taken by me. Credit goes to whoever was behind the camera, and to Ben for letting us use his camera for many of the shots (including the amazing shot of the toad). I have video of the pours, but I haven't gone through it all yet. It will be edited into this post when I get it uploaded.