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 greater the concentration effected by the smelting operation,
the higher is the grade of the matte produced; at the same time, the
actual weight of matte is smaller. On the other hand, since more iron
is oxidised from the charge and slagged off, the quantity of slag
produced increases proportionately. Contrasting then, the likely losses
of copper which would result from the association of a small quantity
of high-grade matte with much slag, compared with those resulting from
the association of a considerable quantity of low-grade matte in the
presence of but little slag, the former condition is obviously the more
productive of heavy loss, for not only will many more shots of matte
be held in suspension, but each shot of high-grade matte represents a
larger quantity of copper.
It is found in practice that it is most economical to make a fairly
low-grade matte on the first or “green-ore” smelting, and to
re-concentrate this matte pyritically up to converter grade by a second
smelting operation. The extra cost of casting the low-grade matte,
of breaking up, rehandling it, and resmelting, with all the extra
charges on capital, etc., involved, is less than the losses which would
be incurred if higher-grade converter matte were made at the first
smelting, although there is no difficulty at all in producing such
mattes so far as the actual furnace operations are concerned. It is
entirely a question of the slag losses involved.
Under ordinary smelting conditions (not truly pyritic), when using
some coke for fuel, it would be readily possible to alter the density
of the slag by adding suitable constituents, such as limestone or
additional silica, but in pyritic smelting this is not practicable.
The furnace chooses to make at the tuyere zone its own slag, and
that a highly basic one. High concentration and a slag low in iron
content cannot be obtained together in true pyritic smelting, since
high concentration means rapid oxidation of iron sulphide, and this
necessitates high temperature and produces a highly ferruginous slag
in consequence. Additional silica added to the charge could not alter
the slag composition markedly and still yield the same grade of matte.
The silica content of the slag depends on the temperature at the
tuyere zone, and this is governed by the rate of oxidation of the iron
sulphide. If the slag is to be more siliceous it must be produced at a
lower temperature, which would be obtained by oxidising the iron less
rapidly. This would lead to the production of low-grade matte, and
probably would so reduce the furnace activity that there would not be
sufficient heat to keep the slag molten.
Public-domain text, read in full here on John Shaqi.
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