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
B. i.—_Avoiding Leakage of Cold Air._—The admission of cold air was the
cause of much waste in the older processes of working. Each time the
doors were opened, either at the fire-box, or during charging on to the
hearth, large quantities of cold air were admitted; air entered through
the working door whilst slag was skimmed off, whilst matte was being
tapped, and whilst the furnace hearth was being clayed; all of which
operations occupied considerable time. The doors were opened during
the levelling down of the fresh charges, and at later periods when the
charge was stirred and the half-fused masses sticking to the bottom
were worked up.
In modern practice, an essential feature of working is to keep all the
doors closed as much as possible, and, as will be indicated shortly,
every means is taken to eliminate the heat losses from the causes just
referred to. Air leakage is also occasioned by bad grating, which
causes the formation of channels in a few parts of the bed of fuel,
admitting excess of air at these places, instead of causing it to come
regularly through the bed in all parts. Channelling is now checked
by the drop of suction-pressure in the flues, as registered by the
manometer.
B. ii.—_Prevention of Radiation through Walls and Roof._—Such heat
losses are now minimised by thickening these parts, and blanketing the
outside of the roof with sand, keeping the construction together by
very heavy bracing.
B. iii.—_Prevention of Cooling of the Hearth on Withdrawal and on
Charging._—By far the most important cause of heat losses in working
was occasioned by the withdrawal of the whole of the melted products,
the charging of fresh cold ores, and the efficiency of the furnace
was very greatly reduced in consequence. In the older methods, fully
three-quarters of the time and fuel, and almost all the labour, were
spent in manipulating the charges and bringing them up to the point
of fusion, the actual smelting operation being responsible for but a
small proportion. The withdrawal of the hot slag and matte abstracts
much of the heat of the furnace, and the cold charge which is fed
in, not only cools the furnace hearth on which it rests, but being a
poor conductor, prevents the heat from again penetrating through it
to the hearth and to the undermost portion of the charge. It has been
estimated through the use of pyrometers, that the temperature in the
furnace after such withdrawal and recharging may drop to less than 700°
C.—a dull red heat—and there is no way under such circumstances of
heating up the hearth again, except by conduction through the charge.
Some hours’ hard firing were thus required to bring the furnace to the
desired temperature again, after which it was necessary to re-open the
working doors, in order to stir the materials so as to prevent the
half-fused masses, still lying on the hearth, from sticking to it. This
also occasioned delay in the operations, and caused much waste of fuel,
heat, and labour.
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