Lead Smelting and Refining, With Some Notes on Lead Mining
Science
Lead Smelting and Refining, With Some Notes on Lead Mining
Lead -- Metallurgy; Lead mines and mining
Referring to the latest history of the H.-H. process, and the theory
of direct blowing, it may be remarked—putting aside all legal
questions—that the idea, metallurgically speaking, is attractive, as it
would seem that by eliminating one-half of the process and blowing the
ores direct without the expense of a preliminary roast a considerable
economy should be effected. Upon examination, however, this supposed
economy and simplicity is not at all of such great importance, and
in many cases, without doubt, would be retrogressive in lead ore
smelting rather than progressive. When costs of roasting in a furnace
are reduced to such a low figure as can be obtained by using 50 ton
furnaces and 10 to 15 ton converters, there is very little margin
for improvement in this direction. From the published accounts of
the Tarnowitz smelting works (the _Engineering and Mining Journal_,
Sept. 23, 1905, Vol. LXXX, p. 535) the cost of mechanical preliminary
roasting cannot exceed 25c. per ton, so that even assuming direct
blowing were as cheap as blowing a properly prepared material, the
total economy would only be the above figure, viz., 25c.; but this is
far from being the case.
Direct blowing of a crude ore is considerably more expensive than
dealing with the H.-H. product, because of necessity the blowing
operation must be carried out slowly and with great care so as to avoid
heavy metal losses, and whereas a pre-roasted ore can be easily blown
in four hours and one man can attend to two or three 10 ton converters,
the direct blowing operation takes from 12 to 18 hours and requires the
continual attention of one man. In the first case the cost of labor
would be: One man at say $3 for 50 tons (at least), i.e., 6c. per
ton, and in the second case one man at $3 for 10 tons (at the best),
i.e., 30c., a difference in favor of pre-roasting of 24c., so that any
possible economy would disappear. Furthermore, as the danger of blowing
upon crude sulphides for 12 or 18 hours is greater as regards metal
losses than a quick operation of four hours, it is very likely that
instead of an economy there would be an increase in cost, owing to a
greater volatilization of metals.
These remarks refer to ordinary lead ores with say 50 per cent. lead
and about 14 per cent. sulphur. With ores, however, such as are
generally treated in the United States the advantages of pre-roasting
are still more evident. These ores contain about 10 to 15 per cent.
lead, 30 to 40 per cent. sulphur, 20 to 30 per cent. iron, 10 per cent.
zinc, 5 per cent. silica, and lose the greater part of the pyritic
sulphur in the preliminary roasting, leaving the iron in the form of
oxide, which in the subsequent blowing operation acts in the same
way as lime. For this reason the addition of extra fluxes, such as
limestone, gypsum, etc., to the original ore is not necessary and only
a useless expense.
Public-domain text, read in full here on John Shaqi.
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