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
Copper—-+
\
+ ➡ Cu_{2}S—+
/ \
Sulphur—+ + ➡ × Cu_{2}S. yFeS ... _Matte_.
\ /
+ ➡ FeS—-—-+
/
Iron——-+
\
+ ➡ FeO——+
/ \
Oxygen—-+ + ➡ × FeO. ySiO_{2} ... _Slag_.
/
Silica ➡ SiO_{2}—+
The copper takes up sufficient sulphur to form Cu_{2}S; the remaining
sulphur combines with any iron which is available, forming FeS. These
two sulphides, dissolving in all proportions, constitute the _matte_
product of smelting.
The iron in excess of that required by the sulphur becomes oxidised,
and the resulting oxide combines with silica in the charge, forming the
silicate _slag_ of the smelting operation.[5]
It will thus be apparent that, in general, the larger the amount of
sulphur present in a furnace charge, the more FeS will there be in the
matte after melting, and the smaller will be the proportion of copper.
In consequence, the grade of the matte will be lower.
The proportion of sulphur in the charge thus controls the concentration
of the copper by the smelting operation, and, in order to effect the
desired concentration, oxygen is required in order to burn off sulphur
and to oxidise iron. There are two general methods of supplying this
necessary oxygen.
(1) By a preliminary oxidation of the charge outside the smelting
furnace—_Roasting_.
(2) By oxidation inside the smelting furnace itself—_The pyritic
principle_ (to be considered later).
=Modern Practice as regards Roasting.=—In modern copper smelting, the
tendency is to do away with roasting as much as possible.
_Objections to Roasting._—(1) Expense involved by a separate
preliminary process. This includes
(_a_) Preparation of the ore for roasting.
(_b_) Extra ground, and plant required for handling.
(_c_) Labour, fuel, etc., required.
(_d_) Extra handling of material before and after roasting.
(2) Heavy mechanical and other losses during the process.
(3) Loss of the fuel value of the iron and sulphur for smelting.
(4) Necessity, in the majority of cases, of having the ore in a
fine state of division in order to conduct efficient roasting, thus
militating against its subsequent use in the blast furnace, unless the
product receives preliminary agglomeration.
Thus at Tennessee, the cost of roasting was about 40 cents, or 1s. 8d.
per ton of ore (equivalent to ½d. on every pound of copper produced).
The cost for the year 1903 amounted to £19,000, employing 170 men
out of a total staff of 900 at mines and smelters. The conditions
for roasting were here exceptionally favourable. The closing of the
roast-yards set at liberty £34,000, which had been tied up in this
manner.
Public-domain text, read in full here on John Shaqi.
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