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
Owing to the high conductivity of copper, and to the fact that the
functions of the furnace are either largely as a medium for simple
fusion or as a receptacle for molten metal, and further, that but
little slag is produced, that no settling and separation of the fluid
materials are required, and that there is no danger of dusting-losses,
the furnace may conveniently be built with a deep hearth which
need not be of very considerable length. The main requirements are
refractoriness of the building materials, particularly careful
construction so as to avoid breakouts, and very strong bracing indeed
on account of the deep and heavy bath of material which is carried on
the furnace hearth.
OPERATIONS—(_a_) _Oxidation Stage._—The furnace is loosely filled with
scrap copper which has accumulated round the works (8 to 12 tons), and
converter metal (of composition say about 98·3 per cent. copper) is
then poured in at the side door from ladles bringing it in quantities
of about 5 tons at a time, as teemed from the converters. When the
furnace is about half-filled, a blast of air at 90 lbs. pressure is
injected through the metal by means of iron pipes, which at this
stage just dip below the surface. These pipes are gradually eaten
away by oxidation and slagging action, but as the end wears down,
the pipe is pushed further in. The function of this air blast is to
supply oxygen for the purpose of acting upon the small quantities of
oxidisable impurity which remain in the metal after bessemerising, and
which consist chiefly of iron and sulphur, in addition to the small
quantities of metalloids. The oxygen partly acts directly on these
constituents, but as already indicated, the scouring action is to a
great extent performed by copper oxide which is produced and which is
itself a powerful oxidising agent. The iron appears to be one of the
first elements to be removed, and then a little sulphur, but this is
chiefly eliminated after the iron has been oxidised. The interaction
between the copper oxide and the sulphides liberates metallic copper
and yields SO_{2}, which bubbles up through the metal and gives to it
an appearance of “boiling,” by which name this stage is known. Too
rapid an oxidation during the early stages is dangerous if much sulphur
be present, owing to the evolution of sulphur-dioxide assuming a degree
of explosive vigour. Up to this point, the oxygen has been utilised
in removing iron, sulphur, etc., which are eliminated as oxides, so
that but little of the oxygen is retained in the metal, but after
the boiling stage is passed, oxygen is actually absorbed, the copper
now becoming oxidised, and the oxygen contents of the metal rapidly
increase. As in the analogous instance of steel bessemerising, it
appears essential to introduce some excess of oxygen into the metal in
order to ensure the complete removal of the oxidisable impurities, so
in copper-refining, an excess which amounts to about 0·7 per cent. of
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