In the _Pattinson_ crystallising process work-lead is melted in open
semi-circular pots: as the pots cool crystals of lead poor in silver form
on the surface and are transferred by a perforated ladle into the next
pot: the silver collects in the small amount of molten lead remaining
behind. Lead that has become enriched by repeated crystallisation
contains a high percentage of silver and is cupelled. The _Parkes’_
process or _zinc de-silverisation_ depends on the formation of a
lead-zinc alloy which is less fusible than lead. Work-lead is melted
and agitated with addition of pure zinc. The crust which first rises on
cooling contains gold, copper, zinc, and lead, and is removed. Further
addition of zinc is then made: the rich silver crust which separates
is subsequently freed from lead by gradual heating in a reverberatory
furnace, and from zinc, in a zinc distilling retort. Other impurities
are got rid of by oxidising in reverberatory or other furnaces. Small
quantities of antimony and arsenic are removed by stirring with fresh
green sticks.
_Zinc_ is obtained principally from blende (sulphide of zinc) and from
calamine (carbonate of zinc). The process of zinc recovery depends on the
production of zinc oxide and reduction of this by carbon to metallic zinc.
Conversion of the ore to zinc oxide is effected by roasting. Since
the temperature at which reduction takes place is higher than the
melting-point of zinc the latter is volatilised (distilled) and must be
condensed in suitable condensers.
Calamine is calcined in a blast furnace. Blende was formerly roasted in
reverberatory furnaces, but such nuisance arose to the neighbourhood from
sulphur dioxide vapour that now Hasenclever-Helbig calcining furnaces
are used. These furnaces furnish a gas so rich in sulphur dioxide that
they serve at once for the production of sulphuric acid. The Hasenclever
furnaces consist of muffles placed one above another: the finely ground
ore is charged through hoppers above and then raked down from muffle to
muffle.
Reduction is carried out in the Belgian or Silesian process by strongly
heating calcined matte with coal in retorts. The zinc as it distils is
caught in special condensing receptacles (prolongs). After distillation
is complete the residue is raked out of the muffle and the furnace
charged afresh. As zinc ores generally contain much lead, the work-zinc
is therefore refined by remelting in a reverberatory furnace, during
which process the impurities collect on the zinc as dross and are removed
by agitation with sal-ammoniac or magnesium chloride.
[Illustration: FIG. 28.—Arrangement of Spelter Furnace showing
Ventilating Hood.]
RISK OF POISONING IN LEAD, SILVER, AND ZINC SMELTING.—As the description
of the manipulations in smelting processes shows, all involve risk of
lead poisoning. As a matter of fact in lead smelting much lead passes
into the atmosphere. In the smelting works at Tarnowitz yearly some
36,000 kilos of oxidised lead escape.
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