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 importance of the iron contents of the matte from the viewpoint of
converter practice is due to iron being the chief source of heat in the
operations, and to the fact that the iron oxide produced from it is the
constituent which requires a supply of flux in order that the reactions
may proceed and the process be successfully operated. The economic
limit to the grade of matte suitable for the converter process is
reached when it becomes less costly and more profitable to supply the
required siliceous flux for the iron in the ordinary smelting furnace
rather than in the converter. So long as the destruction of the lining
was practically the only medium by which silica could be efficiently
supplied, the limit to the iron contents of the matte was fairly rigid.
The bessemerising of a low-grade matte (low in copper contents, high in
iron) entails the great advantage that a high temperature is obtained,
owing to the fuel-value of the iron. On the other hand, however, grave
disadvantages attend such practice, especially when working with the
comparatively small quantities of material usually operated, and when
employing siliceous linings. These disadvantages include the factors
that—
(_a_) Large quantities of iron oxide are formed, which
require siliceous flux.
(_b_) Large quantities of highly ferruginous slag are
produced which carry copper values, and which also
demand special attention in operating.
(_c_) The quantity of copper obtained is comparatively
small, thus increasing the proportionate losses
and working difficulties.
In bessemerising a high-grade matte, the heat production is much
smaller, owing to the decrease in the quantity of iron, which is the
chief fuel of the process, and the limiting grade is quickly reached
above which the bessemerising operation upon the matte ceases to be
self-supporting.
In consequence, up to a comparatively recent date, a compromise has
necessarily been effected, and the grade of matte operated upon has
been such as to cause as much heat production as possible, together
with the smallest practicable amount of fluxing action.
On these grounds, a matte containing from 40 to 50 per cent. of copper
(equivalent to 32 to 22 per cent. of iron) has been found generally the
most suitable. At several smelters, lower-grade mattes of from 32 to 40
per cent. copper-contents are converted most profitably, owing to such
special circumstances as the profits resulting from the destruction of
lining material, or in consequence of the fact that greater operating
costs would be involved in concentrating the matte to a higher grade by
the ordinary furnace-smelting methods.
In this connection, the successful adaptation of the basic lining by
permitting the supplying of flux by means other than from the linings,
has very important application and possibilities.
Public-domain text, read in full here on John Shaqi.
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