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
As will be seen from the plan (Fig. 42), the smelting works cluster
in terraces around the mine shaft, covering an area of about 3000 sq.
m. (0.75 acre); the ore stocks and the pottery of the zinc works are
located in separate buildings.
During the first years of working, the slag had purposely been kept
very rich in zinc, in the hope of utilizing it later for the production
of zinc oxide. It had an average zinc content of 16.80 per cent., or 21
per cent. of zinc oxide, with about 32 per cent. SiO₂, 25 per cent.
FeO, and 14 per cent. lime. According to the recent experiments, this
slag can very well be used for oxide manufacture, in connection with
calamine rich in iron. The slag made at the present time has only 15
per cent. ZnO; 25 per cent. SiO₂; 16 per cent. CaO; 3 per cent. MgO;
33 per cent. FeO; 2.5 per cent. Al₂O₃, and 2 per cent. BaO, and
small quantities of alkalies, sulphur and lead (1 to 1.5 per cent).
The following classes of ore are produced at Monteponi:
1. Lead carbonates, with a little zinc oxide; these ores are screened
down to 10 mm. The portion held back by the screen is sent straight
to the shaft furnaces; the portion passing through is either roasted
together with lead sulphides, or is sintered by itself, according to
circumstances.
2. Dry lead ores, mostly quartz, with 10 to 15 per cent. lead, which
are mixed for smelting with the lead carbonates.
[Illustration: FIG. 42.—General Plan of Works.]
3. Lead sulphides, which are crushed fine and roasted dead. Quartz
sand is added in the roasting, in order to decompose the lead sulphate
and produce a readily fusible silicate; as quartz flux, fine sand from
the dunes on the coast is used. This is a product of decomposition of
trachyte, and contains 88 per cent. of silica, together with alkalies
and alumina. The roast is effected in two hand-raked reverberatory
furnaces, 18 m. long, which turn out 12,000 kg. of roasted ore in
24 hours, consuming 1800 kg. of English cannel coal, or 2400 kg.
of Sardinian lignite. There is also a third reverberatory furnace,
provided with a fusion chamber, which is used for roasting matte and
for liquating various secondary products.
The charge for the shaft furnace, as a rule, consists of 50 per cent.
ore (crude and roasted), 20 per cent. fluxes and 30 per cent. slag
of suitable origin. The fluxes used are limestone from the mine,
containing 98 per cent. CaCO₃, and limonite from the calamine
deposits. This iron ore contains 48 per cent. Fe, not more than 4 per
cent. Zn, a little lead and traces of copper and silver.
A shaft furnace will work up a charge of 60 tons, equal to 30 tons of
ore, in 24 hours, with a coke consumption of 12 per cent. of the weight
of the charge and a blast pressure of 50 mm. of mercury. There are
three furnaces, of which two are used alternately for smelting lead
ores, while one smaller furnace serves for smelting down products, such
as hard lead, copper matte and copper bottoms.
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