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
For sampling the Vezin apparatus is used, cutting out one-fifth in
each of three passes, crushing intervening, the sample from the third
machine being 1/625 of the original ore; after further comminution of
sample in a coffee-mill grinder, it is cut down further by hand, using
a riffle. The final sample is bucked down to pass an 80-mesh sieve, but
gold ores are put through a 120-mesh.
The steps in the smelting process are as follows: Roasting the poorer
ores in reverberatory furnaces and in Brückner cylinders. Smelting
raw and roasted ores, mixed, in water-jacketed blast furnaces,
for work-lead and lead-copper matte, the latter containing 15 per
cent. lead and 10 to 12 per cent. copper. Roasting the ground
matte, containing 22 per cent. of sulphur, down to ¾ per cent. in
reverberatory furnaces. Smelting the roasted matte together with acid
flux in the blast furnace for a matte with 45 per cent. copper and 12
per cent. lead.
Only the pyritic ores are roasted in Brückner furnaces, the lead ores
and matte being roasted in reverberatory furnaces. Each of the 20
Brückner furnaces, which constitute one battery, roasts 8 to 12 tons
of ore in 24 hours down to 5½ to 6 per cent. sulphur, with a coal
consumption of two tons. The charge weighs 24 tons. The furnaces make
one turn in 40 minutes. To increase the draft and the output, steam
at 40 lb. pressure is blown in through a pipe; this has, however,
resulted in increasing the quantity of flue dust to 10 to 15 per cent.
of the ore charged. Ten furnaces are attended by one workman with one
assistant, working in eight-hour shifts. For firing and withdrawing the
charge five men are required.
The gases from the Brückners and reverberatory furnaces pass into a
dust-flue 14 × 14 ft. in section and 600 ft. long, built of brickwork,
with concrete vault; in the stack (225 ft. high, 20 ft. diameter) they
unite with the shaft-furnace gases, the temperature of which is only 60
deg.
There are 12 reverberatory furnaces with hearths 60 ft. long and 16
ft. broad. They roast 14 tons of ore (or 13 tons of matte) in 24 hours
down to 3½ to 4 per cent. sulphur, consuming 32 to 34 per cent. of coal
figured on the weight of the charge. There are 12 working doors on each
side. The small coal (from Rock Springs, Wyoming), which is burnt on
flat grates, contains 5 per cent. ash and 3 to 5 per cent. moisture.
The roasted product is dumped through an opening in the hearth,
ordinarily kept closed with an iron plate, into cars which are raised
by electricity on a self-acting inclined plane. Their content is then
tipped over into a chute and cooled by sprinkling with water. From here
the roasted matte is conveyed to the blast furnace in 30-ton cars. The
roasted ore is tipped into the ore-bins.
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