In a shot tower, lead is heated until molten, then dropped through a copper sieve high in the tower. The liquid lead forms tiny spherical balls by surface tension, then solidifies as it falls. The partially cooled balls are caught at the floor of the tower in a water-filled basin. The now fully cooled balls are checked for roundness and sorted by size; those that are "out of round" are remelted. A slightly inclined table is used for checking roundness. To make larger shot sizes, a copper sieve with larger holes is used. However, the maximum size is limited by the height of the tower, because larger shot sizes must fall farther to cool. A polishing with a slight amount of graphite is necessary for lubrication and to prevent oxidation.
The process was invented by William Watts of Bristol, UK, and patented in 1782. The same year, Watts extended his house in Redcliffe, Bristol to build the first shot tower. Shot towers replaced the earlier techniques of casting shot in moulds, which was expensive, or of dripping molten lead into water barrels, which produced insufficiently spherical balls. Large shot which could not be made by the shot tower were made by tumbling pieces of cut lead sheet in a barrel until round.
The "wind tower" method, patented in 1848 by the T.O LeRoy Company of New York City, which used a blast of cold air to dramatically shorten the drop necessary meant that tall shot towers became unnecessary, but many were still constructed into the late 1880s, and two surviving examples date from 1916 and 1969. Since the 1960s the Bliemeister method is used to make smaller shot sizes, and larger sizes are made by the cold swaging process of feeding calibrated lengths of wire into hemispherical dies and stamping them into spheres.
- Drop tube, a similar concept, but used for scientific experiments
- Prill, a small granule of material formed by a similar process to shot-making. Often used in the chemical industry for solid chemicals.
- Spray drying is a process of turning liquids into powder; many spray dryers also have the drops of liquid solidifying as they drop in a tower.
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|Wikimedia Commons has media related to Shot towers.|
- "Gravity Molds Shot In A Modern Tower", October 1944, Popular Science detailed and large article on subject of Shot Towers