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 sintered cakes are finally discharged automatically into cars.
Details regarding the machine vary at different smelters; at one works
the length is 30 feet, the rate of travel 8 inches per minute, and the
vacuum in the suction chamber 6 ozs.
The size of the particles should not exceed ¼ inch, and not more than
25 per cent. of the charge should be so large. Some 3 to 5 per cent.
tends to pass through the grids, and so be drawn into the suction
chamber; this is cleared out at intervals through special doors. Water
is necessary, and from 6 to 10 per cent. must be employed in uniformly
moistening the charge, which, by the addition of suitable fluxes,
is often made of such proportions that in subsequent blast-furnace
smelting a satisfactory slag is produced without further additions. The
sulphur reduction by the process is very considerable.
[Illustration: Fig. 16.—Dwight-Lloyd Sintering Machine.]
Such blast-roasting methods, with suitable modifications, promise to
assume considerable importance in the developments of modern smelting
practice.
_c._ =Roasting.=—Roasting is often a very important preliminary stage
in the scheme of treatment of copper ores. It was formerly considered
an essential operation in smelting processes for sulphide ores, the
material being crushed and concentrated largely with a view to such
subsequent treatment. This is not the practice in modern smelting.
Roasting is now only conducted where the necessity for it arises, as
in the case where wet dressing, having been considered advisable, has
resulted in the production of large amounts of fine concentrate, and
where reverberatory furnaces are installed for the smelting of this
material. Preliminary roasting of the concentrates then conduces to the
production of a matte of converter grade in one smelting operation.
=The Principles of Copper Smelting.=—Copper extraction from sulphide
ores is essentially an oxidation process, the iron and sulphur being
oxidised and the oxide of iron slagged away. All such smelting
processes, both the older and the more modern ones, are based on this
fact, and underlying all of them are certain fundamental principles
which it is essential to keep in mind in considering every phase of the
subject.
These may be summarised as follows:—
(1) In the melting down of a furnace charge, the copper has first claim
on any sulphur which may be present.
(2) Only such sulphur as remains in excess after the copper has been
satisfied, is free to combine with other constituents of the charge.
These fundamental principles can best be illustrated by following the
reactions during the smelting of a typical charge. Thus—
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