Smelting: Three-Day Direct Method
The three-day direct method of smelting was only practiced in the Okuizumo region. Through years of trial and error, ironworkers were able to improve on the four-day method and develop a process that required only three days.
The direct smelting method used a superior iron sand called masa in combination with akome iron sand. Masa iron sand, which comes from acidic rock, has fewer impurities but melts at a much higher temperature. Unlike the indirect method, which produced molten pig iron that oozed out from the furnace, the main product of the direct method remained inside the furnace as a large, porous lump of iron and steel called a kera. At the end of an operation, the furnace would be dismantled and the kera smashed apart and sorted by grade. This was the only method capable of producing tamahagane steel, which is vital to the production of Japanese swords.
Records from the Kanna Ironworks (Okuizumo, Shimane Prefecture) show the materials consumed during a single instance of the three-day method in 1901: 13.5 metric tons of iron sand (masa and akome) and roughly 14 metric tons of charcoal were used to produce 2.1 metric tons of pig iron and a kera weighing 2 metric tons, meaning that about 30 percent of the iron sand was converted to usable metal.