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
If extra silica be added to the charge, it would probably be unattacked
unless more iron were oxidised in order to flux it off. In such a case
the blast would have to be increased in order to produce iron oxide
more rapidly, the temperature would in consequence be raised, a still
more basic slag would be produced in larger quantity, whilst the matte
would be increased in grade and reduced proportionally in weight.
The addition of sufficient lime to the charge, in order to produce a
sufficiently low-gravity slag, is also impracticable in true pyritic
work, because—
(_a_) The extra lime consumes silica, and interferes with the
desired reactions at the bessemerising zone, tending to lower the
concentration. It also absorbs heat.
Lime has a very powerful affinity for silica, more strongly marked
than that of iron oxide, its replacing value is higher, its more
siliceous silicates are readily formed and they have a lower formation
temperature, all of which factors tend to an undue consumption of
silica which is urgently required by the iron if the rate of oxidation
is to be maintained. The marked tendency for lime in the charge to
consume the silica tends to retard the oxidation of the iron sulphide,
which proceeds most satisfactorily when free silica is available for
the nascent iron-oxide, and in consequence concentration is decreased
and the heating effect in the furnace reduced. In addition, the larger
bulk of calcareous slag carries considerable heat from the smelting
zone of the furnace. Lime silicates and the polybasic lime slags have
a markedly lower formation temperature than the normal ferruginous
slags of true pyritic smelting, they are hence formed readily without
requiring so much oxidation activity at the tuyere zone. In consequence
less iron is oxidised, and the resulting concentration in the matte is
proportionately reduced.
(_b_) The lime is introduced in the form of limestone, and the carbon
dioxide liberated from this material in the furnace is found to have a
deleterious effect on the furnace gases if the manufacture of sulphuric
acid from them is intended—this being a consideration of great economic
importance in connection with many modern pyritic smelters.
Hence, in practice, pyritic smelting is at present generally conducted
in two stages for the production of a matte of 30, 40, or 50 per cent.
converter grade. The “green ore-matte,” or first matte, runs usually
from 8 to 13 or 14 per cent. of copper, depending upon the copper ore
available, which is usually very low grade—2 to 3 per cent. copper
contents; the second or concentrated matte assays 28 to 40 per cent.
copper. Special care is taken to ensure good settling of matte from
the basic and irony slags, and by these means the copper losses in the
slags are reduced to the comparatively moderate proportions associated
with normal practice.
Public-domain text, read in full here on John Shaqi.
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