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
At first the roasting was done mainly by hand roasters; later two
Brown-O’Harra mechanical furnaces were used, and the cost was reduced,
but not to the extent usually conceded to this type of furnace, as the
large amount of repairs and the consequent loss of time diminished
the apparent gain due to greater output. The figures quoted above may
be considered somewhat higher than the average, as the roasters were
charged in proportion with expenses of general management, office, etc.
In viewing the yearly reduction of costs one must take into
consideration many changes in the furnace construction and working, as
well as the items of labor, fuel, etc. From 1887 to 1899 the principal
changes in the construction of the hand-roasting furnaces consisted
in an increase of width, 2 ft., which allowed an addition of 200 lb.
to each ore charge, and corresponded to a total increase per furnace
of 1200 lb. in 24 hours. In the working of the charge an important
change was made in the condition of the product. Formerly the material
was fused in the fusion-box and drawn from the furnace in a fused or
slagged condition; and while this gave an excellent material for the
subsequent treatment in the shaft furnace in that there was very little
dusting of the charge, and a considerable increase in the output of the
furnace, the disadvantages of large losses of lead and silver greatly
over-balanced the advantages, and called for an entire abandonment of
the fusion-box. As a result of experience it was found that the best
condition of product is a semi-fused or sintered state, in which the
particles of roasted ore have been compressed by pounding the material,
which has been drawn into the slag pots, with a heavy iron disk. The
amount of “fines” under these conditions is quite small and depends
upon the percentage of lead in the ore, the degree of heat employed,
and the extent of the compression.
The total cost was partly reduced from the lessened labor cost
following the financial disturbance of 1893, and partly from the
reduction in the fuel cost, the former expensive lump coal being
replaced by the slack coals from southern Colorado.
The comparison of the cost of labor by the two methods shows a gain of
54c. a ton in favor of the mechanical furnaces. However, I consider
that this gain is a costly one, and is more than offset by the large
amount of high-grade fuel required, and the expense of repairs not
shown in the following table. Indeed, I believe that at the end of five
or ten years the average cost of roasting per ton by the hand roasters
will be even smaller than by these mechanical roasters.
To illustrate the details of roasting cost and to furnish a comparison
of the hand roasters and mechanical furnaces, the following table has
been prepared:
DETAILS OF AVERAGE MONTHLY COST FOR 1898 OF HAND ROASTERS AND
MECHANICAL FURNACES
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