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
=The Chief Features in the Development of Modern Copper Smelting
Practice.=—In the early days of copper smelting, the reduction of the
oxidised ores, which were then chiefly available, was not a problem
of very great difficulty, although losses in slag were likely to be
very high, and the operation generally wasteful. When, however, mines
became deeper and sulphide ores had to be smelted, the problem became
rather more complicated. In the first stages of development, such
ores were probably roasted until as much sulphur as possible had been
driven off, leaving practically an oxide charge to be treated by the
older reduction methods involving the attendant extravagance in fuel
consumption and large losses of copper in the slag.
From these crude and wasteful methods the Welsh process was gradually
worked out, and it will ever rank as one of the finest examples of
highly developed smelting practice in the history of metallurgy,
particularly when the times and working conditions are borne in mind.
The process having received such full treatment from most of the common
text-books, it is not proposed to review it in detail here, since,
moreover, it has been largely superseded by more modern processes.
As will be explained later, copper smelting of sulphide ores is
essentially a fractional oxidation—chiefly of iron and sulphur—followed
by the slagging or elimination of extraneous constituents of the ore.
The Welsh process embodied a series of roastings and slaggings which,
though most admirably adjusted for a substantial concentration of the
copper in each succeeding product, allowed of the formation of slags
in the first stages which carried but comparatively little copper, on
account of the low tenor of the matte; whilst the slags in the later
stages of the process, containing more copper on account of their
association with higher grade matte, were made in such relatively small
quantity that their re-treatment for the recovery of these values did
not involve very much loss of efficiency in the furnace operations.
Later modifications of the process were chiefly devised with the view
to reducing the number of operations, by eliminating the successive
roasting stages, for which purpose oxidised materials, such as roasted
or oxidised ores, were added to the charge.
The Best-Selecting process, and the Nicholl and James process are
likewise valuable and ingenious modifications of the Swansea method for
special work.
In general, however, up to 1880, there had taken place but little
change in principle from the older methods of smelting. The chief
improvements involved a slow change in furnace size, and progress in
several details in practice. The more important of these advances were—
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