Modern Copper Smelting: being lectures delivered at Birmingham University, greatly extended and adapted and with and introduction on the history, uses and properties of copper.Levy, Donald M.
Science
Modern Copper Smelting: being lectures delivered at Birmingham University, greatly extended and adapted and with and introduction on the history, uses and properties of copper.
Levy, Donald M.
Copper -- Metallurgy
(_a_) The supply of heat required for the smelting of the charge and
the thorough fusion of the products depends entirely on the intense
combustion of the iron and sulphur constituents, and the greater the
proportion of these materials oxidised per minute, the higher is the
temperature. As has been already noted, such heat intensity increases
at a rate greater than the mere arithmetical increase in the fuel
proportion, by reason of well-known thermo-chemical laws regarding
mass effects. Indirectly, too, the higher the proportions of sulphides
present, the smaller is the quantity of inert or useless matter which
requires to be heated and slagged off in the furnace—apart from the
question of the necessary flux material. Hence the higher the iron and
sulphur contents of the ore, the more successfully may true pyritic
smelting be applied to it. True pyritic smelting may be said to cease
when carbonaceous fuel requires to be burnt at the tuyere zone in
order to supplement the heat derived from the sulphides, and broadly
speaking, from about 28 per cent. of iron and about 30 per cent.
of sulphur are necessary in the charge for good pyritic work under
present conditions. At Tennessee, with about these proportions, the
coke consumption on the charge is reduced to about 3 to 4 per cent.;
at Mt. Lyell, where the ore runs from 40 per cent. of iron with a
corresponding quantity of sulphur, the coke consumption amounts to
only about 1·25 per cent. None of this coke probably reaches the
bessemerising zone at all.
(_b_) Being supplied with enough sulphide fuel, the requisite quantity
of air for the rapid and sufficient combustion of this iron and sulphur
is essential. The oxygen is used up entirely in the bessemerising of
the sulphides at the tuyere zone of the furnace, and in consequence,
not only the heat supply, but also the concentration depends upon
the amount of oxygen furnished at this point, since the greater the
quantity of oxygen which is used up, the greater is the amount of
sulphur eliminated and the amount of iron oxidised and slagged off,
and in consequence, the higher is the proportion of copper in the
resulting matte. In other words, the oxygen supply largely controls
the concentration effected in the smelting process, and consequently
an adequate quantity is of the utmost importance. The amount of air
theoretically required per minute is readily calculated from the
estimated capacity of the furnace and from the charge analysis. Liberal
allowances are required for losses, leakages, blower efficiency, etc.;
and the volume necessary at the furnace amounts to something like 5,000
cubic feet per minute per 100 tons of sulphide.
Public-domain text, read in full here on John Shaqi.
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