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
In order to deal with such a large quantity of charge in this bulky
form, without occupying so much time as to make the whole operation
too protracted, it is usual to employ some form of charging machine
rather than to use hand labour for the operation. In some cases a small
melting furnace is employed solely for the purpose of preparing the
metal in a molten form for feeding into the refining furnace. The type
of cathode-charger most used is very similar in operation to the Welman
charger for steel furnaces, and by its means, 100 tons of material can
be charged per hour.
_Operation._—The refining and toughening process is conducted in the
six stages of:—
(_a_) Charging.
(_b_) Melting.
(_c_) Skimming.
(_d_) Oxidation, by aëration.
(_e_) Reduction, by poling.
(_f_) Casting.
(_a_) The charging is sometimes conducted in stages, this being indeed
unavoidable when very large quantities of material are worked with, the
bulk of which, when solid, would more than fill the furnace. Two-thirds
or three-quarters of the material may be put in at first and just
melted down slowly, after which the remainder is added.
Owing to the not infrequent presence of sulphur in the furnace coals,
and to its ready affinity for copper, resulting in undesirable
consequences for the commercial metal, contamination by this element
is usually prevented, as much as possible, by giving to the cathodes a
wash of lime previous to charging.
(_b_) The melting is generally conducted somewhat slowly, so as to
allow some oxidation of the metal during this stage, which may occupy
some twelve hours. Skimming of slag as it forms, and subsequent blowing
of the copper towards the end of the melting stage are frequently
resorted to.
(_c_) The slag which accumulates, sometimes in considerable quantity,
is skimmed off as occasion requires. When converter metal of such
purity as not to need electrolytic refining is treated directly in
the furnace, much of this slag is converter-slag introduced from the
ladle, and requires to be skimmed off at an early stage. In the usual
process of melting cathode-copper, slag is produced from the last
traces of iron which may have remained in the metal. In order to render
it sufficiently viscid to be pulled out by the skimmer, ashes from the
fire-grate are thrown upon and rabbled into the slag. This skimming may
continue for some time, and a very rich coppery slag is pulled off,
from which the metal values are subsequently recovered.
(_d_) The oxidation of the small quantities of impurity still remaining
in the metal is completed by the operation of airing, as already
described, and the action is continued in order to produce a small
excess of oxide until the copper is “dry.” The time occupied for this
airing is now not very protracted, since most of the impurities have
been previously removed from the metal.
Public-domain text, read in full here on John Shaqi.
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